Construction of a sandwich wall by wet process
In the previous episode, Matt surveyed the shape of his boat to make a template for the new bulkhead he wants to install. He can now start making the bulkhead, in sandwich composite, as he did with the rest of the boat originally.
As is often the case on personal jobsites, Matt uses the wet fabrication technique, vacuum infusion being more delicate. He protects himself with a mask and a suit before applying two layers of fiberglass cloth to a 1 inch thick divinycell foam board. With the help of a friend, he impregnates them with epoxy resin before adding a peel ply. He then performs the same operation on the other side and lets the resin cure.
Once the air cure is complete, he uses his template to trace the shape of the new wall before cutting it with a jigsaw.
Visualization of the ship's fittings
Matt then installs the bulkhead in the boat. Apart from a few minor adjustments and cuts, it fits perfectly in the location determined during the dimensioning process. Matt can now make the second symmetrical half bulkhead.
The young handyman sailor can start to visualize the future accommodations that he traces with a felt pen on the bulkhead: doghouse benches, engine hold, watch seat and manhole to access it...
