Well I've sorted it in my mind and I'll do a complete set of new foils. I have some new spare stocks and materials to make connectors and there's a spare tiller extn. in the shed which, while a tad short can easily be lengthened.
The old foils [first out of the moulds] were a little rough and a bit heavy and the d/boards always leaked.

FWIW,
I've been thinking about the reason for the mishap and it occurs to me that since cranking the rig back, and powering up the mast, I've loaded the rudders with more pressure, increasing the flexing of the pintle pins sufficiently to cause the retainer clips to bend and release the rudders. It's all I can think of given that the system has not failed till now after 7yrs of racing.

Bern