Getting my head around how to create enough buoyancy in the boat, I juggled the idea of simply using inflatable lifting bodies (which I still may use) or installing bulkheads - which in addition may contribute to body rigidity of the entire structure. Also I like the idea of having some storage room etc. - all that beer on the fishing trips needs to go somewhere :-)
As for some reason I decided to use as little plywood as possible with the boat, I also wanted to make the bulkheads form solid Mahogany.
First step obviously is to create the exact pattern / template for the external shape of the bulkheads. I found the method as shown e.g. by
Louis Sauzedde https://www.youtube.com/watch?v=cj3K9i9nLrE
the most easy for me.
The video explains it all, basically it works with using self-adhesive labels and a rough cut piece of cardboard:
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKFZ9ijw_fsRLgoSzReKBMurAy8WA6ZSD7V7D9CvsKjop5RQVRKNbwtZfID0UEQKPw2ZGBNHVukeHi-RFUSSUOS1xLJ0RMBMUXvT7Pc7X9OY0PhLlmCjN2dXdBr92wzw9Y_1aLykfWg7I/s1600/IMAG1156.jpg) |
sticky labels to create the exact shape |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCSoiyIMou5F5bTIFGyF-qHb0_ueboRO9w-yxQwfkrcApEvTzP6ZGwio8Dvh6WjWsZTkHH1IX77gDFYzoYQnus-dzZkZr_ZnYaATn_CiLWHS1i7-UxrH5HDIOxuBuwHiDWxso09pSkkzk/s1600/IMAG1160.jpg) |
and the final patterns. |
Next step was milling the lumber for the actual bulkheads. I used Mahogany milled to 9mm (actually the boards are the "leftovers" from boards I had sawn already to thickness for future use as the stern of the boat.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgW608CwDAr771gBGruRUdgcE6ZHNkguxvXsAb6Q06G6BuhXfFnByLpPZtTGOThcbnsfqry7XeEn-3YhDvHiGrjJkM1dxrZKGywXu53w2tkWme3zGq4LyTG6jf7D9iliknrxMpIpdYTsN0/s1600/IMAG1162.jpg) |
Lumber prepared... |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4VwIqvUumrB-ZavRcjMUGt17Yh1SkANHR6kgNHSolSXHJi3Dflf90yvA6g6OWKnAg7-f94vvi3xmamnAkKDpeS5zum945g0lndBQkRoi-GRsINcygwurkScub0_5s0vyusLuamOOcyCo/s1600/IMAG1165.jpg) |
Jig for cutting the mortises and tenons on the table saw |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicTwKCY85pGi0Q0NH4TkYimA5ManLGQrv0aE3phHDKHoMHOQ5223EDvWaGiFB3kBxcugp4xaUtTELGq5gFEg4u5iMR6A0XQmiOOQZ-sFi0mJnsw12p6pv8TxOJM2sOgG82p3lwtjT8UaE/s1600/IMAG1173.jpg) |
one of the two front bulkheads |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcuZIEalP1fgtxeK5PNcawkXbrHEBRzp4y-u5NTEAef5pNYKjRQywU2YjWVFm96iomAcgIHlbDYdXAHt890Q0MnYHL5-eC5dpCxru2ULBDwaWkfhJHI0dXq_obuYZ4TYK2qJsgeTwcsI0/s1600/IMAG1175.jpg) |
Aft bulkhead |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOemfv-tto-PETLjgFc3Z_Dh_SEbYPU6rfGFA3oI6ORE3O_aNMk_AeO7HJFsPLM0PbAUH9oWQepVsIt1YDIwLxeVHHDt8JJZb7HpA_JgWuCMM9dLgth_-T2IDmfUBgXnYFdIosr_dxG_Y/s1600/IMAG1187.jpg) |
After glue-up |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdU51xOM0vi7aKX7gFAI-Gx6w_4A6dKAjd7H-ArEixW__JqkQ37NSF3FTedINDCt0gY72PMCVRveAt08jXwV6cGasTEhBW0Za95a43nNM8afoqTS_pjgxpi2jMl4ylLTg8ac2svaiFYY0/s1600/IMAG1188.jpg) |
Marking the saw line with a pencil |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioGGKZe6uHgYH9njlgvyhPJzo83ARF8RSCQWHfuenjQFx8kpMmGZ83LUPQjbZ0Z2KQhVMq7w7QkfLG19BPG7ZicppRt6r39eeHyB_wSa04zpfqBmXb-J6Eh0akgS04DT2ZIn_5uxcSxm0/s1600/IMAG1208.jpg) |
and here is the cutting line |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhLBTZ-Wx6dYZB0yk8UfJFnaJWZL4w2JaoGmFVjfhXbR5Yf06yS8-xa9LoHgoeQQjBs16nfKuf_COvb2YDQrPsd6XIHm9vwmmyNFRRIHbZ6bI1jQ4gnAP833nxOqNTSirXOsts9GjUz0I/s1600/IMAG1192.jpg) |
Dry-fitting |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjguxgmXAq0-geHYQADy4ID_M0ScxOAswL7qbBkxdTBuxUSg8v0joS2oezWRQiE2N15sIIq47Pl7-uel_r8-UJRYBe1luycrHAEb4RBjXqJ6x6yij_XLjqPRaITKr6jCYPg_X7LUkASIG8/s1600/IMAG1209.jpg) |
Final fit and gluing into place |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioKT8vvovkdiDGzbPXstb_PeTbWnUgp6oVZ0iVdWDwMbjNz2wKXmKIwExvTI0E3j3EYMPMfoueqW32bXJOq3q0XALgKiMhGoUpsYbdD26sjwQBA4GJDTGR7wImfjjhGHwaCyr1ibO6hO4/s1600/IMAG1223.jpg) |
same for the aft bulkhead. The solid spruce and ash pieces are already rough cut elements of the rear deck structure |
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