i. First measurement should be from the bottom of the
panel, to the center line of the bulkhead for the height
dimension. (see picture #1)
ii. The second measurement should be taken from the
right side of the panel to the center line of the bulkhead
for the width dimension. (see picture #1)
iii. Once the center of the bulkhead has been laid out,
the full bulkhead dimensions can be laid out. When laying
out the bulkhead 1-1/2” must be added to the overall
length and width of the bulkhead. (i.e. if a 10”
x 10” bulkhead is required, the dimensions drawn
on the inside of the panel should be 11-1/2” x
11-1/2”) This dimension should be laid out on center,
so that ½ the bulkhead is on either side of the
center line for both the height and width. (see picture
#2)
iv. Using a 2” hole saw drill the four corners
of the bulkhead so that the hole saw makes a neat outside
radius for the corners. (Drill on an angle just through
inner skin see picture #3)
v. Continue to cut through the straight sections of
fiberglass (note: approximately ¼” thick)
with a cutting
grinding, up to the radius corners. Remove top layer
of fiberglass. (refer to picture #4) Lift off the cut
glass
(picture #5)
vi. Using a knife mark out the actual bulkhead size
in the foam, should be ¾” inside of the
cut fiberglass all the
way around the bulkhead. (see picture #6)
vii. Remove the foam in the bulkhead area with the knife.
Grind both inside and outside with 100 grit paper. (see
picture #7 & #8)
viii. The remaining foam on the inside of the cut fiberglass
can be sanded smooth with 100-grit sandpaper, creating
a rounded edge. (see picture #9)
ix. Using catalyzed thick mix (resin and fillers) spread
the mixture to cover all exposed foam areas. (see picture
#10)
x. Sand thick mix once it has cured, so that the fiberglass
and resin laid over top will adhere properly.
xi. Cut three layers fiberglass in 6” strips to
go all around the perimeter of the radius. Then cut
3 layers glass the area of the bulkhead.
xii. Mix up hot coat and catalyze.
xiii. Wet out the bulkhead with resin before laying
any glass down, using a standard paint brush
xiv. Wet out first layer of fiberglass using catalyzed
hot coat, and put into place. This step can be done
using a small brush and a mohair roller.
xv. Repeat the above listed steps for the next two layers.
xvi. Once dried, sand with 200-grit sandpaper.
xvii. Final hot coat. Two coats. Using finish hot coat.
Hot coat is usually performed over the entire panel,
to avoid a patchy look upon completion.
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