Bulkhead Repair proposal - SailNet Community
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post #1 of 7 Old 09-30-2013 Thread Starter
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Bulkhead Repair proposal

I've got a bulkhead with some rot near the deck due to leaking where the chainplates pierce the deck.

My plan was to cut out the upper section of the bulkhead with at a 9 or 10 to 1 angle and scarf in a new piece of teak-veneered 1" marine ply. I'd then reglass the area where the bulkhead meets the deck.

There's a designed 1/4" gap between the outboard edge of the bulkhead and the hull in the affected area. The only glass cut would be at the top.

I ran out of time to do the project and asked the shop in the yard to take a look. They want to rebuild the bulkhead in Airex-cored glass.

I'm uncomfortable with this for a few reasons:
1: I don't know anything about Airex.
2: The matching bulkhead on the port side is teak veneered marine plywood and I like the look
3: I'm not sure it's OK to have different materials between the two bulkheads. Won't they flex differently?
4: I think the mismatch will ruin the resale value of the boat

Am I crazy to want this rebuilt with materials similar to the original design? Are my concerns reasonable?

1975 Tartan 30 Competition Rig
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post #2 of 7 Old 09-30-2013
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Re: Bulkhead Repair proposal

Your concerns are reasonable.
I don't think you'll have much luck trying to scarf a piece in.
I'd just tear the whole bulkhead out instead of trying to replace a piece of it.
If the upper half is toast, chances are the bottom of it where it's glassed to the hull is trashed also.
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post #3 of 7 Old 09-30-2013
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Re: Bulkhead Repair proposal



it took a LOT more than i thought to find GOOD WOOD as the water goes through 100% of the wet ply depending on the layers orientation









I USED G-FLEX on the wood and normal epoxy on the tabbing andd jsut finished the third season with zero issues
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Last edited by tommays; 09-30-2013 at 05:44 PM.
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post #4 of 7 Old 10-01-2013
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Re: Bulkhead Repair proposal

Nice work, as always, Tommays.

You should read Dan Witucki's good article in Epoxyworks.com called "Replacing Damaged Bulkheads". Witucki was not as focused on maintaining the existing appearance, replacing the bulkhead with G-10. Certainly the prime concerns must adequate strength and stability. Perhaps you could apply teak veneer to the replacement to achieve the appearance you wish.
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post #5 of 7 Old 10-01-2013
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Re: Bulkhead Repair proposal

Misfit is right - take the whole thing out - it's easier than farting around trying to replace part of it and it'll be a much better final result.

I, myself, personally intend to continue being outspoken and opinionated, intolerant of all fanatics, fools and ignoramuses, deeply suspicious of all those who have "found the answer" and on my bad days, downright rude.
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post #6 of 7 Old 10-01-2013
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Re: Bulkhead Repair proposal

eko-
On a Tartan30 I would expect the bulkhead to be small enough that you could get a piece of proper marine ply or timber to replace it, with less work and more reliability and the same aesthetics as the original.
Getting the wood can be a PITA as marine-grade lumber isn't common. There's condonlumber.net in White Plains, NY, and I have no idea of any sources closer to you. So picking it up, or having it shipped, is a PITA.
But if you can get the old one out fairly intact, or make a template before removing it, then fabbing up the new one is fairly simple.

Replacing it with something that simply can't ever rot (frp, with or without any core) isn't a bad idea but there's no reason a craftsman could do that AND pay a wood veneer over it, so that it was an aesthetic match as well. That would probably be the "best" way to go but I suspect the frp guys don't know how to work with veneer, or they would have offered that to you.
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post #7 of 7 Old 10-01-2013
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Re: Bulkhead Repair proposal

There are hardwood lumberyards everywhere. Check with local cabinet shops if you aren't in range of saltwater. It ain't only boatbuilders that use nice wood, in fact they use very little of it.

I, myself, personally intend to continue being outspoken and opinionated, intolerant of all fanatics, fools and ignoramuses, deeply suspicious of all those who have "found the answer" and on my bad days, downright rude.
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