We had a similar problem with our S2 7.9's. When I tried to purchase a new rudder from S2 (Tiara Yachts now) I was quoted $5000. My solution was to get a mold made and build my own, as the class did not require us to purchase from S2 which has the original molds. The S2 class decided to start weighting rudders at the nationals to establish an acceptable weight and prevent people from building a 'cheater' super light weight rudder.
Anyhow, I would have to say that $2500 or so is not unreasonable for a new rudder from the builder. It cost me about $600 in materials (not including mold construction) plus about 60 hours of labor to make a rudder (60 hrs x $20/hr = 1200 bucks.) I have sold 2 for 2K each and I figure I am letting them go cheap. My point here is be carefull of what materials and craftmanship go in a cheap rudder--they usually only break when it's blowing 20+!!. I know one S2 7.9 that had one built for $1000 and it broke in half.
My suggestion would be to get your class association to build and own the molds and then rent them to owners or hire some local reliable glass-man who knows the boat to build 5 or 10 as a batch (cheaper that way) to sell to class members.
PS still looking for a J30 of my own...
Frank
