... I located the same Collar from Tides Marine that SG suggested, they have the part in Lauderdale, all machined and ready to go, I'm couple hours away and need to go there anyway, so will grab that. Thanks again SG ... that should be a good replacement.

I bought a 3/4" thick x 6"x6" sheet of Delrin AF from MMC, should be here tomorrow, will have that machined locally.

Hoping to get at this next couple days, will keep you posted. I'm thinking if that alum collar doesn't come off, I made try the Fein tool and make a few vertical cuts and hopefully pry it off.

All the while keeping my rudder supported by way of emergency tiller access and hope it doesn't fall out.

Cheers, John