I find it very easy to get the size right.
Since all my kayaks (since the first two) have been designed with Kayak Foundry, I just add a bulkhead to the design at the right position and print it out.
That's a real time-saver.
Can you print the pattern on a home printer (tiled) and tape the sheets together, or do you need to take it to a print shop?
Also, can you print the pattern for a bulkhead that's inclined at 75 degrees for use as a footboard? That would save a lot of fitting work.
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- Strip: bulkhead shape