New Cabin Bulkhead
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The original Bertram bulkhead was only a single thickness of 1/2" plywood and only screwed into the fiberglass without any tabbing...
The new bulkhead will be two thickness' of 1/2" plywood, laminated both sides with heavy laminate. All processes, including the laminate will be done with epoxy.
Using the original bulkhead sections as templates, the exterior sections were constructed. Held temporarily in place, the interior sections were templated using door skin strips. The two sections were then epoxied together, laminated, and checked for fit.
 Once the two sections are laminated together, a router template is attached to cut open the window. The opening is rough cut with a jig saw.  A rabbet is routed into the interior of the window opening to accept the 1/4" tempered plate glass wondow. This is done after the laminate has been added to both sides of the bulkhead.  Exterior view of installed bulkhead sections. |
 The bulkhead is flipped over and the finished opening is accomplished with a router fitted with a ball bearing straight cut bit.  The exterior opening is rounded over and all exposed wood is epoxy sealed. The door opening was adjust to be 23" and the two small molding samples seen here are for the finished styles which will reduce the door opening to it's normal width.  Interior view of installed bulkhead sections. |
Several noticeable features seen within these images are:
- Engine beds and bilge fairing have been started.
- Outboard engine space shelves are being installed at the chine line.
- Cabrera V-berth unit has been installed.
- Sweep opening has been cut to replace the original V-berth entry.
- Transom livewell has been installed.
- The front windows have been converted to fiberglass.