This is a rudder that we made to replace a broken one. We proposed the customer to replace it with a laminated one. Under vacuum we glued together two panels to make up the required thickness. Then two oversized holes were bored and filled with hardened and toughened epoxy. Under vacuum we laminated the rudder with S2-glass. The sprayed finish was polished to a #1200 grid, enough for the speed range the rudder was going to be used in. For the moment we can polish up to #4000.
For really high-performance rudders we use carbon to make the laminate, other planforms, and different NACA profiles such as 0010, 0012 or 63012 ...