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Interior Bulkheads and Furniture

Structural bulkheads construction and structures will need to be coved with a high density mixture of WEST SYSTEM brand resin/hardener and 403 Microfibre Blend, and fibreglass taped into position.  Non-structural bulkhead construction and interior furniture with no loading may be coved with a low density mixture of WEST SYSTEM brand resin/hardener and 411 Microsphere Blend and taped into position.

It will be much easier to make modules on your workbench rather than inside the boat.  Once the parts have been released from DuFLEX panels, they should be joined, coved, and glassed in the usual manner.  Edge detailing of the panels will be a new task.

Edge detailing is the removal of the core on exposed edges of the parts and replacing it with a low density epoxy compound of WEST SYSTEM brand resin/ hardener and 411 Microsphere Blend.

Once the modular part is assembled, it should be dry- fitted to check the positioning and shape.  Remove to the workbench to cove and tape the joins, and coat the surfaces.  Once the joints have cured the part can then be permanently fitted in the boat.

For large curved pieces of furniture, such as cockpit or saloon seating, the DuFLEX panels can be kerffed to achieve the required shape.  To make each of the radiused corners, run a portable circular saw against a plywood straightedge, through the core to the inside of the outside laminate.  The kerfs vary depending on the desired bend, so it is a good idea to draw the shape on the floor of the area it will be positioned and make a temporary jig of the curve required.  To determine the distance between the cuts - look for the flat spots in the curve on the floor and measure.

For balsa and foam cored panels, a mixture of WEST SYSTEM brand resin/hardener and 403 Microfibre Blend should be spread into the open cuts: the panel is then bent over a temporary jig of its final shape and temporarily clamped until the epoxy cures.  A layer of fibreglass of the same weight and orientation should be applied to the retain the full strength of the part.

Featherlight panels can be kerfed with a metal disk for cutting stainless steel.  The finer blade removes the requirement to backfill, and you just laminate a layer of fibreglass of the same weight as the original laminate to hold the shape.  You will have much neater edges on the kerfs if you leave the peel ply in place when you are cutting.

Download Featherlight / Honeycomb data sheet (468 KB)

Download Featherlight / Airex C52.60 data sheet (81.8 KB)