[Paddlewise] Making a foam bulkhead

Dave:

I installed a forward bulkhead in my Dagger Edisto with total success. 
Three years now, including all-winter paddling in Michigan and no
problems.  While I was at it, I installed a larger VCP front hatch, and
sealed the leaky factory-installed rear bulkhead.
Use stiff copper wire to get your first approximation of the shape of
the desired bulkhead.  Trace that onto corrugated cardboard, and tweak
it into final shape.  Make the bulkead from 2-3" minicell foam.  Make it
a tiny bit oversize, so it will fit like a cork.  You can even taper it
t conform to the hull taper, using a rasp, Sur-form, or Dragon Skin.  

Use medium-grit sandpaper to rough up a strip about 1/2" wide along the
inside of the hull, adjacent to the bulkhead, for better adhesion. 
Clean the area with prep solvent (like acetone), wipe clean of all grit
and residue (use good ventilation!). 

 Run a generous bead of 3M 5200 Quick Cure Marine Sealant/Adhesive
along the line where hull and bulkhead meet.  Shoot a little extra goo
into any gaps between them.  Use a moistened thumb to smooth the goo
into a clean fillet.  You have about 3 hours working time according to
the instructions, but don't plan on touching it after the first hour. 
Allow to cure 24 hours. Do not try this in a workspace cooler than
60oF.
If you can do this on both sides of the bulkhead, so much the better.

3M 5200 Quick Cure is available in standard caulking-gun tubes, about
$10-12, from any good marine hardware.  Accept no substitutes.  Silicone
or latex bathtub sealant is useless in these applications.  You should
be able to get minicell foam from a good kayak store, especially if they
deal in whitewater boats.

Good luck,
Dan Harrison
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