Installing Primary Bulkhead (Port)

March 3, 2019

I picked up where I had left off in the previous work session - completion of the port side primary bulkhead.  I laid the door skin template of the port primary bulkhead on the fresh sheet of 3/4" meranti plywood, and secured it in place with a couple clamps.  From there, I traced the template onto the meranti, and then used a small compass to transfer a few adjustments to what would be the final bulkhead.  In test-fitting the rough / door skin template, I noticed a few areas that would need some adjustment, so at that time I took note and made reference marks to account for the needed adjustments.

With the template transferred to the sheet of meranti, as well as the minor adjustments that I had accounted for, I cut out the new port side primary bulkhead.

I brought the bulkhead over to the Allied 24, and with sanding tools at hand, I worked to fine tune the fit of the new port side primary bulkhead.  A primary focus for me was a good installation of the bulkhead so that the integrated mast support beam would transfer weight onto the bulkhead and ultimately onto the hull of the boat.  The primary bulkheads would be tabbed to the overhead and hull, and would help transfer and spread the load of the mast. 

I placed the mid-ships chainplate in position to help align the bulkhead, but noticed that the prior positioning of the bulkhead as related to the chainplate was not optimal.  The Allied 24's orientation in the work yard is in a bow up position, and working out that compensation revealed that the chainplate would need a shim to then provide a good mounting foundation.  

Satisfied with the placement and position of the bulkhead, I used a hot glue gun and small wood blocks to "lock in" the position of the bulkhead.

I used the saloon settee as the aft framing structure for the bulkhead, and after manipulating the alignment of the bulkhead, I then used the wood blocks as the forward alignment points.  The hot glue gun is an extremely useful tool for the solo refit specialist, the perfect tool to place alignment blocks! 

Satisfied with the alignment, I removed the bulkhead and vacuumed and solvent-washed the work surfaces. I then painted neat epoxy on to the outboard surface of the bulkhead as well as the hull surface itself.  

I then mixed a couple pots of thickened epoxy to spread onto the hull surface where in which the bulkhead would make contact.  

With the thickened epoxy placed onto the hull and overhead surfaces, I set the bulkhead in position.  I worked the squeeze out thickened epoxy into the small gaps here and there, making sure that the bulkhead was in good contact with the hull and overhead surfaces either directly or through the thickened epoxy mixture.  My final task was to create a fillet between the bulkhead and overhead/hull surfaces to create a radius that the eventual tabbing would lay down nicely on.  The fillet prevents harsh angles, allowing for the fiberglass tabbing to make good contact from bulkhead to overhead/hull.  My next task for the port side primary bulkhead will be water-washing and sanding to prep for tabbing it onto the hull/overhead.

Total Time Today: 4.25 hrs