bulkhead repairs

[Ardenfour]

the lower shroud chainplates on my trintella 29 have leaked water for years by the look of it, and this has caused the forward bulkhead edges where they were attached to almost disintegrate. I've removed chainplates and all interior joinery and lining to get access to the area and to cut out the outer 6 inches of the bulkhead, back to good wood. I'm unsure of the best way to attach the new pieces to the old. The wood to hull bond is straightforward enough, but how to join the new and old ply edges together to retain strength across the whole bulkhead? I could epoxy and tape the join, but, when built up to the necessary thickness this won't look too pretty - is this the correct way to do it, or has anyone any other ideas?
thanks

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[Spuddy]

Well here's my toopennorth. Bulkhead is obviously a bit crucial structurally - under tension from chain plates etc plus hull stiffening ? Sounds like you plan to scribe in some new ply to fit the hull sides and glass it in. So the bond to the existing bulkhead needs to maintain strength. Haven't a clue how thick a layer of cloth you would need to lay over the joint to get that strength. Another option is putting that bit in as a filler and then another wider strip over the top to overlap the bulkhead - epoxy and screw through from the less noticeable side - could look like some panel framing as a disguise. Would that lead to problems with refitting the lining?
Just got up for acup of tea - you gave me something to do in the early hours
regards....spuddy

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[snowleopard]

this is a serious structural problem and cosmetics have to come second. a boat we met had a failure in that area and the deck started lifting - in mid-atlantic.

you have to transmit the forces to the main part of the bulkhead, the new piece wandering around on its own will probably pull the deck off.

the most effective way is to strip back the whole side area of the bulkhead to clean bare wood and bond reinforcement to it with epoxy. the best reinforcement for this job is carbon fibre but glass fibre will do if you can't get it. stitched bi or tri-axial fabric is best, failing that woven roving but definietely not chopped strand mat. i would spread the bond over not less than 2ft of the bulkhead, preferably a lot more. the amount of fibre you use depends on the rig loads but i would suggest a minimum of 500 gsm carbon each side, double that if glass is used.

after applying the reinforcement you can tidy up with car body filler and paint it all so you'll barely notice the bulge.

p.s. if water has been weeping through around the chainplates they may have corroded in the area that was within the deck. stainless can rust if damp and shielded from contact with air.

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