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Bertram31.com General Bulletin Board
Re: patterns *LINK* *PIC*
Posted By: Capt Partick McCrary In Response To: patterns (toyota 4)
Date: Saturday, 10 December 2005, at 8:05 p.m.
T,
The stock companion way door opening is 19" & dead center over the keel. To make templates for the bulkhead cut a 1/4" thick sheet of cheap plywood, (Lowe's $10 for a 4x8 sheet), into 2" x 8' strips. (More than you need by a long shot, but you'll use it all by the time you finish...)
Pencil in a line from port to stbd on the hull & across the stringers, (presuming that the partial fwd engine bulkheads are also removed). This line should plumb below the bulkhead pocket under the overhang.
Armed with a hot glue gun & a jig saw, begin cutting and fitting strips, on edge, to your pencil lines. You'll be making four templates:
Port bulkhead, stbd bulkhead, center bilge bulkhead, & a header over the door opening.
Work the templates so that they follow every surface. Use numerous diagonals to keep the template true and rigid.
Once the templates are made, (marked port & stbd), trace out them out on your plywood. The stock bulkhead was 1/2", I recomend at least 3/4". I used two pieces of 1/2" laminated together with thickened epoxy on "Buddy Boy" for a 1" thickness...
Cut back 1/2" of the bulkhead edges that will be following the hull sides. You need a gap there in order NOT to have a hard spot in the hull. Any tabbing between the bulkhead and hull will be done by just bridging the tabbing.
Figure your window design, cut the openings, and prefit the bulkheads. Once you're happy with the fit, laminate both sides with heavy Formica style laminate. Use thickened epoxy for this process, at least on the exterior side.
Leave a 3" margin of raw wood on all edges that will be bonded to the hull for your tabbing.
Screw & epoxy the bulkheads into place. Recess the screw heads & fill over later. Tab the bulkheads to the hull with 6" 1708 biaxle tape. Tabbing isn't necessary above the hull line. Use epoxy fillets to finish these joints. (Topic covered in the Tips Section.)
As mentioned on the phone yesterday, you've come to the right spot for "Been there, Done that" support for project.
Where are you located, & did yo' Momma really name you Toyota??
Best regards, and good luck on your "new" B31.
Patrick
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