Ok I have been able to bite the bullet thanks to my wife and crew. We have just purchased the materials to start building a carbon/foam rudder that will be built out of a mold.
It will be seriously sexy and if all goes according to plan we should have it ready for the weekend after next.
carbon layup consists of;
200gms twill--1m
408gms DB--2m
300gms UD--8m
The cassette for this rudder will be made from 408gms UD about 1.5m worth
A BIG THANKS again to CG Composites & Allwood Sails in Brisbane.