Here is a situation. So I smear some unthickened epoxy on all the inside surfaces of my rudder-head, make up a pot at mustard consistency, glue up, and clamp away. Remove clamps, the rudder blade doesn't go in! There is no internal obstruction---if I push hard enough I can get the thing arbitrarily close to where it should eventually live---but no way is it swinging up and down on its hinge bolt. This is before I've smeared additional epoxy on the rudder blade, and way before I've decided whether to finish it bright or painted, and done so; neither of these steps is going to reduce the thickness of the blade, needless to say, and I was hoping to get some paint inside the rudder head, fiberglass on the leading edge, etc.
Should I have incorporated some kind of shim into my glue-up for the rudder head? Can I salvage the pieces I have now without using a power sander (which I do not own) on the blade? If not, I imagine CLC can send me a new rudder head, but can anyone suggest a way to save the original one?