Originally Posted by Finallybuyingaboat
Okay, although I have done this before, what are your guys advice on some bulkhead replacement questions.
I will be using 3/4 inch Mahogany plywood. I will be putting closed cell foam between the bulkhead and hull and will angle the edges of it for a slow radius for the cloth at the corners. I will be sealing the ends of the plywood with epoxy prior to installing.
My Questions are:
1) What weight fiberglass cloth to use,6 oz or 10 oz?
2) How many layers of cloth; I was thinking 3.
At least three of 10 oz. or four of 6 oz.
3) Should I brush some epoxy onto the plywood face to wet it a bit where the cloth will be laid down?
4) Should I put the cloth on and then brush on the epoxy or should I wet the cloth in the epoxy tray and tranfer it? Any tricks to avoid major messes here?
You can do it either way... the trick is not to oversaturate the cloth. You want just enough resin to wet out the cloth, but no more... I would recommend putting the cloth on the wetted out bulkhead, and then using a foam roller to add epoxy and help wet out the cloth. Rollers work better than brushes IMHO.
5) If I am putting on 3 layers, can I just go one after another, or should I wait for it to set up a bit?
It might be wise to wait a bit between layers, since doing all the layers at the same time might cause them to sag. This is especially true if you're using too much resin to wet the cloth out.
6) will epoxy adhere to polyester resin? Looks like the old bulkheads were put in with polyester. I will grind off as much as humanly possible, but do not want to risk grinding gouges in the hull, so there may be some polyester still on the hull.
Epoxy will stick to pretty much anything... that's the reason it is used for high-strength structural repairs, and polyester/vinylester resins generally aren't.
Any other tricks/tips are appreciated, as I said I have done this before, but better to plan thoroughly now rather than regret poor decisions later.
If it makes a difference, the boat is a Shark 24 from 1961.
Get and wear a full tyvek bunny suit with hood, gloves and use a good full-face respirator, like a 3M 6000 Series, with a plastic cover for the faceshield. This will help prevent you from turning into a sticky mess, and help keep you from itching from the ground fiberglass, or reacting to the epoxy.
A good source for epoxy is Progressive Epoxy Polymers
, in NH.