Bulkhead Repair

While its too cold to do any fiberglass layup, its not too cold to cut the new bulkheads out and prep the boat for the repair.  Using the old bulkhead, I traced a template onto cardboard and cut it out.  I test fitted it to validate size.  I fit well.  I then took the template and placed it on my new sheet of AC grade 3/4 plywood.  For you southerners, the white stuff is the snow I will have on my driveway until March.

I used a standard jig saw to cut the template out.  I was able to save the trim from the old bulkheads and will be reused on the new.  Note the new bulkhead leaning against the Desperado ground support vehicle.

I repeated the process for the aft bulkhead using 1/2 AC.  Sorry no pics for that.

I then donned my respirator, goggles, coveralls, hat and gloves and entered Desperado with a angle grinder.  This is by far the nastiest part of the job, prepping the hull for receiving the new bulkheads.   I ground down the remaining tape and all paint off the tape bound to the hull.  The combination of noise, dust and general unpleasantness really made me want to finish this step in one session.  I got everything done in about an hour except the keel sump as the angle grinder wouldn't fit.  Got to get another tool.  There is currently about 1/4 inch of nasty, fine white dust in the boat coating everything.  Sorry no pics as I didn't want to expose my digital camera to such a hostile environment.  If you decide to do this, get a quality respirator and ear plugs!  When I get her cleaned up, I will take some shots of the prep work.