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Bulkhead replacement

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crcalhoon
Captain

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USA
303 Posts

Initially Posted - 01/14/2006 : 18:43:12

Has anyone ever replaced the after interior bulkheads, the ones containing the upper shroud chainplates? It doesn't look too difficult, but then. . .

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Steve Milby
Past Commodore

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USA
5902 Posts

Response Posted - 01/15/2006 : 09:24:46

I've never done it, but I know it has been done. Someone who has done it will probably offer some suggestions. Now that you mention it, if you do the job, it would be helpful to others if you'll take a few photos, write it up, and post it in tech tips.

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Frank Hopper
Past Commodore

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Pitcairn Island
6776 Posts

Response Posted - 01/15/2006 : 15:05:06

I have not done it either but I do not believe they are under a compression load when the boat is at rest and the chainplates are unloaded.

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Happy D
Admiral

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921 Posts

Response Posted - 01/15/2006 : 20:34:41

I'm doing it right now. It is pretty strait forward. No surprises. Finding teak plywood that looked nice was the challenge for me. Of course the mast has to be down.
Once I removed the existing bulkheads, I removed the plastic trim/piping or whatever that stuff is Catalina used to trim the edge of the wood with. I put the bulkheads back in place and used a little block of wood to move along the edge and traced a new line on the old bulkhead. Then when I laid the old bulkhead on the new plywood, I use the little block of wood to trace exactly where the edge of the wood meets the fiberglass liner. This produces a much nicer fit. The edge where the plywood meets the liner is not a 90-deg angle. It is tapered so cut the piece big and sand it for a nice fit. Of course this requires 100 trips in and out of the boat.
I did not use the original screw holes Catalina used to fasten the new bulkheads. I drilled new holes and added several more of them.
When drilling the holes in the new plywood, I drilled almost all the way through with a brad point drill, just until the tip poked through, and then finished the hole from the other side. This prevents splintering of the veneer.
When I drilled the fiberglass for the new screw holes, I chamfered the holes just a little with a counter sink so the gelcoat didn’t crack at the screw hole. I hate those cracks.
The original screws Catalina used were 2” long and that is about 1” too long. I bought all new screws.
I also found that the washer cuts into the teak veneer. Placing a ¼” stainless washer under the finish washer gives the screw a flat surface to bear against but it isn’t visible under the finish washer.
There is a blue plastic filler piece inside the flange that the bulkhead screws to. This provides lots of screw engagement and a good strong hold.
I did not find the bulkheads under compression, but the compression post is. I had to use a jack to get it out. I removed it for a different project. The compression post needs to be in place to do the bulkheads.
Removing the trim piece from the edge of the starboard bulkhead was easy. I placed it vertically against the side of my workbench and banged it along the trim piece on both sides until the glue let go and it slipped off. It did crack and I just glued it back. The crack is not visible.
I can supply a picture of anything if you need, just drop me e-mail. I posted some info here but didn’t go into detail.
http://home.wmis.net/%7Edhapp/teak/teak.html

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Leon Sisson
Master Marine Consultant

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USA
1893 Posts

Response Posted - 01/15/2006 : 21:17:57

Good description, Dan. Nicely detailed.

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crcalhoon
Captain

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USA
303 Posts

Response Posted - 01/15/2006 : 21:50:34

Dan--Well, I guess that stops me for now. I had not thought about having to unstep the mast. I'm still not really clear on the necessity, though. The compression post doesn't have to come out, and it looks as though the bulkhead will just unscrew. There must be a lot of pressure on it holding it in place. I had anticipated the problem with finding teak ply, where did you find yours?
Guess I could just stain some oak or birch. Our lake level is so low that no one will be hauled or launched for months if we don't get some serious rain. I guess I will have to put this on the back burner for now. PO added a patch of half inch ply on the after face of the bulkhead to reinforce the chainplate, and it seems pretty well done and strong enough, I just didn't like the looks of all that rot at the bottom. Ah well, the project list just grows and grows. Thanks

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Happy D
Admiral

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921 Posts

Response Posted - 01/15/2006 : 22:18:22

I found Teak Plywood at Public Lumber in Detroit, Mi. The wood was excellent, for what you get today. You could use any wood you want. I stayed with the teak becasue I'm not replacing all the bulkheads, just the main two that the chainplates are bolted to. I love cherry but could not find any 1/2" cherry plywood anywhere. Our bulkheads are 1/2" thick.
John Vining replaced the [url="http://www.geocities.com/neebish1904/projectboat5.html"]bulkheads[/url] in his Columbia with birch plywood and it is beautiful.
I suppose you don't have to lower the mast, but the shrouds will have to be released to get the chainplates out. It took me about 2 1/2 deays to do this and my boat is sitting <i>in</i> the wood shop. I wouldn't want the shrouds left loose for too long. I suppose you could tie the halyard off while working on that side.
The bulkheads do just unscrew. Also, there is some plumbing that goes through the starboard bulkhead at the bottom. At least there is on mine.
Good Luck,
Dan

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Dan86
Navigator

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130 Posts

Response Posted - 01/16/2006 : 06:42:39

I did my starbard bulkhead last year with 3/4 marine plywood with the edges camphered down to fit. I also coated the end grain with epoxy to prevent any water intrusion. Any hardware holes I had I overdrilled filled with epoxy and drilled to fit. Came out very well with stain and sealer on top. Dan

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John V.
Admiral

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USA
559 Posts

Response Posted - 01/19/2006 : 22:47:08

Hey Dan,
Thanks for posting the link to my columbia restoration I was going to suggest a link, and there you are doing my promotions for me.
I suggest using the back button a few clicks to show the method I used to cut out the new bulkheads. I hope your windows are going well.

Still recovering from the auto wreck, and havn't done much work on the boat for over 6 weeks. I need to get started again.
A note to all who restore, maintain and sail their OWN boats, Bravo and again Bravo. To me there is nothing besides sailing quite as rewarding as fixing up a boat.

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The Officers, Staff and members of this site only provide information based upon the concept that anyone utilizing this information does so at their own risk and holds harmless all contributors to this site.