Back Up Against a Wall - Bulkheads Fixed

One of the many casualties of continual water leakage in Harmony was the rotting of bulkheads in the galley/dinette area.  On the starboard side, both forward and aft bulkheads were compromised.  On the port side, the aft bulkhead which separate the dinette from the engine room was damaged, as well.

Starboard Side - Aft Galley Bulkhead removed

After verifying that the structural integrity of the vessel wasn't lost, the focus shifted to the removal and either replacement or repair.  The galley bulkheads needed to be removed, but the dinette bulkhead, thankfully, just needed repair. 

Port Side - Aft Dinette Bulkhead with damaged area removed

The bulkhead between the dinette and engine room was a major component for supporting the cockpit, and while cut into at many spots, the dry rot and delamination was confined to where the previously mentioned holding tanks was installed.

Once removed the Galley bulkheads were solid enough to use as templates to create the replacement panels.  I used 3/4' Merranti plywood procured from Boulter Plywood in Somerville, MA, a Valhalla for a hardwood addict.  The Merranti plywood, while not possessing the beauty of other mahogany panels is resistant to water damage and takes a better paint finish than standard marine plywood.

Forward Galley Bulkhead replaced with 3/4" Merranti

One the forward side of the galley, I needed to accommodate a teak post that serves as a deck support and a hand hold.  On the aft side, I had to interface with the navigation station and the underside of the side deck. 

Aft Galley Bulkhead of 3/4" Merranti tabbed and glassed to the Hull

Once the patterns were scribed and cut, it was a simple process of sistering, tabbing, and glassing to the hull.  The strongest tabbing was made with a smooth fillet of foam and epoxy followed with 10 ounce glass tape and West System epoxy.

The Aft Dinette bulkhead required a different process.  Since I didn't need to remove the bulkhead, I needed to install an overlay.  However, this overlay needed to be tabbed and glassed to the hull.  By bonding the overlay panel to the existing bulkhead with screws and epoxy coupled with the tabbing to the hull, the new "laminated", if you will, bulkhead would act as one.  Later on, I would through-bolt this laminated bulkhead to 1.5 x 1.5 inch mahogany studs in the engine room between and upon which I installed Soundown sound proofing and wall panels, respectively.

Aft Dinette Bulkhead installed - cables supply an electric Lewmar winch

The critical action with this bulkhead was the scribing to the hull shape to give the foam and glass fillet/tabbing a consistent surface for strong bonding.  I used regular marine plywood because the surfaces would be hidden within the dinette furniture.

Teak post back in place at the forward end of the Galley

When all the panels were install, I only had to re-install the teak post.  It was an amazing transformation when I looked at the repaired area complete with new decking in the galley/dinette area.

Looking Aft from the Salon into the "new" Galley/Dinette area

While there is a long way to go with many things to still do, seeing the progress gives a huge lift to one's spirits.

Fair Winds and Following Seas!