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if we were to re-engineer this thing (and then I could have a 'big' rudder like you guys...) what would you think about manufacturing a center 'spine' that captures the mounting pintels, and continues to the base of the rudder. Then the faired thickness could be bonded to the spine (perhaps styrofoam or high density stuff, sort of like making a surfboard) to create the shape of the lower portion. and then wrap the whole with fiberglass??
Sounds like a lot of work...
Maybe I'll just learn to live with my beautiful mahogany stick! It NEVER collects water.
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