Micro-balloons to prevent hard spots.

[Freerider]

Can I use a mixture of epoxy and micro-balloons with a 1" fillet, for bonding knees to the hull? I don't want to bond the plywood directly to the hull with high density filler because i don't want to create a hard spot.

I know using foam between the plywood and hull will work as well, but I was thinking it would be easier to just use a layer of micro-balloons between the wood and hull, and a wide fillet to spread the load. The glass over top will provide the strength.

Any idea's if this will work?

[mitiempo]

The foam is used to prevent any hard spots between the hull and bulkhead as things flex and move - and they will. The method you suggest will not keep the bulkhead away from the hull as it should be.

I have used foam cut in a way to help create a fillet. In other words the foam against the bulkhead is as wide as the ply is thick and it widens where it touches the hull. Hold it in place with hot glue. This way the load is handled by the tabbing exclusively with no chance the bulkhead will ever touch the hull. Saves on epoxy as well.