: Anyone have any ideas of how to make / install a wooden bulkhead in such a
: way as to not create a stress riser?

: I have not been able to find any solutions I felt were good and wanted to
: find a good alternative to using the minicell foam.

: Doug

I like the idea of curving the glass. Like take Dale's dwg step #3 and fillet the low foam side (say its on the cockpit side) and add curved glass. Say 1in offset and radius. You get the stiffness of the foam, the security of glass and possibly up to 2 in of give. The glass is in tension for pump foot strokes or filled cockpit w/ water. Maybe use polyester, dynel or kevlar instead of glass for real flexibility w/o failure. Maybe (from hatch side) jam bulkhead in place (1in free all around) w/ scrap pcs of foam, spray expanding urethane foam all around the edge, fillet w/ sandpaper from cockpit side, add glass fillets, scrape out foam from hatch side - only use the glass.

Or if you really know the i/s profile at the bulkhead location, make it all up o/s the yak, and mask off the hanging edge of the glass. Unmask, push in place, and wet out the cloth just like 'painting' the i/s seam using Jay babina's approach.

the bulkhead end grain should be sealed.

-mick