We build rudders with passion and precision since 1963.

ships anywhere

cost effective

satisfaction guaranteed

3 photos of foss foam rudders
1963

about us.

In the early sixties, an innovative man named Chuck Foss developed several polyurethane foam systems useful for a variety of purposes, including the production of surfboards. His new firm, The Foss Company, soon became one of the top U.S. suppliers of foam surfboard blanks, which he sold under the name of “Foss Foam.”

Later in the sixties, one of his Foss Foam systems used to make surfboard skags was found to be a excellent material for making sailboat rudders. It was not long before The Foss Company was supplying rudders to most of the boat builders in Southern California. 

The Foss Company’s former headquarters. During the eighties and nineties, the company specialized in fiberglass and foam composites. High performance sailboards and paddleboards were some of the products produced. With an extensive inventory of rudder molds, the company now specializes in supplying sailboat owners and boat repair yards with replacement rudders.

In recent years, The Foss Company has formed a strategic partnership with FinCo Fabrication, a major fiberglass manufacturing firm based in Santa Ana, California. This partnership will assure that The Foss Company’s long tradition of quality products and service will continue for years to come.

Boats

Our focus.

We make rudders and dagger boards for most sailboats, working with existing molds.
A custom design rudder can be made just for you and your boat.
CAL yachts logo
CAL YACHTS

CAL 20
CAL 25
CAL 28
CAL 34
CAL 40

Catalina boats logo
CATALINA YACHTS

CAPRI 18
CATALINA 22
CATALINA 25
CATALINA 250
CATALINA 30
CATALINA 45

Ericson Yachts logo
ERICSON YACHTS

Ericson 35
Ericson 38
Ericson 41
Ericson 46

beneteau yacht logo
BENETEAU

Oceanis 37
Oceanis 46.1
Beneteau 56

Manufatures A-C

Balboa Yachts
B-Boats
Beneteau
Catalina Yachts
Cal Boats
Coronado Yachts
Columbia Yachts
Coastal Recreation
Chrysler Yachts
Corsair Marine
C & C Yachts

Manufatures D-L

Down East Yachts
Ericson Yachts
Hunter
Hobie Cat
Irwin Yachts
Islander Yachts
J Boats J24
Kirby Boats
Kettenburg Marine
Lancer Yachts
Laguna Yachts

Manufatures M-R

Merit Marine
Morgan Marine
MacGregor Yachts
Newport Boats
Olsen Boats
O’Day Boats
Pearson Yachts
Pacific Sea Craft
Ranger Yacht
Reynolds Sailing

Manufatures S-Z

Sam Morse Boat Company
San Juan Boats
Sidelmann
Tarten Marine
W. D. Schock Boats
Westsail Marine
Westerly Marine
Willard Boats

Start your rudder with us now (714) 973-2878 or (949)646-0244

Great Old Boats - Cal 40's New Rudder

Click to open video

Details

Our manufacturing process.

Our special manufacturing process assures that our rudders are strong, light and dependable, ready for a lifetime of sailing pleasure.
1

Design

Working together with you the owner we select an exciting mold or sketch out a new design for a  custom rudder. All based off years of experience and time tested best practices.

Rudder for cal 40 design
2

Prepping mold

Experienced Finco craftsmen begin the manufacturing process by sanding, polishing and waxing the rudder mold.

Prepping the rudder mold.
3

Gelcoat & first layer

After applying Gelcoat to the mold, they apply a layer of unidirectional fiberglass saturated with Vinylester™ resin.

Gelcoat the mold
4

Rudder Shaft Turned​

A new rudder shaft is turned from the same material as the original (or stronger.) After it is cut to length and tapered, the tangs are welded into place.

new rudder shaft
5

Shaft set & foam+

Once the fiberglass has cured, the tapered stainless steel shaft is set into the mold. After the shaft is aligned, the halves are mated, clamped and sealed, and liquid foam is poured into the mold.

setting the rudder shaft
6

Sand to Smooth

When the foam has cured, the rudder is removed and the seams sanded smooth. Most OEM rudder fabrication stops here; we go farther.

sand
7

Taped and cured

Fiberglass tape is laminated to the seams. After the tape has cured and has been sanded smooth, the rudder gets a final coat of gelcoat.

Sand
8

Faired & prepped

In the last step, the entire rudder is faired and sanded in preparation for you to apply a coat of bottom paint.

Sand and gelcoat
9

Packed in custom box

The finished rudder is packed in a purpose-built crate suitable for shipping to you anywhere in the world.

Rudder in box

Start your rudder with us now (714) 973-2878 or (949)646-0244

Best

Why Select Us?

We understand your unique requirements and provide quality work that lasts.
Original
OEM Tooling

We have many of the original molds and tooling for production boats made over the mast 60+ years in our inventory and can replace damaged rudders with the exact factory replacement. If you would like a custom rudder, we can modify or design from scratch a rudder that meets your exact needs. 

crimp
"Clam-shell" Method+
Smart Advancements

The original rudders originally were manufactured by “clam-shell” method and our exact replacements use the same tooling. Plus over the years there have been advances in glass cloth and in laminating resins making them stronger and more reliable. The closed cell foam core of the rudder remains the same, but the selective addition of unidirectional fibers has increased the strength of our rudders, and the use of Vinylester™ resins has eliminated blisters and the need for expensive barrier coats.

Ultimate
Performance Upgrades

Newer designs to improve handling and directional control. This is most important when sailing very fast and can help prevent broaching and spin-outs. Most boats can use upgraded rudders without incurring a rating penalty. Some local PHRF boards will hit some designs with a 3 seconds-per-mile penalty so you should check with your local board before making your change.​

Start your rudder with us now (714) 973-2878 or (949)646-0244

Start

Get in Touch

Start your next dream adventure or race with a new Foss rudder.
Here for you

Phone: (714) 973-2878
(949) 646-0244
Email: finco@sbcglobal.net

About us

Foss Rudders fondued in 1963 has partnered with FinCo Fabrication, a major fiberglass manufacturing firm in Santa Ana, California. We make precision rudders for you.

Where to find us

2520 South Broadway, Santa Ana CA 92707