We first made a jig to ensure the new bulkhead remained accurate to the original design.
Once the jig was complete, we dismantled the old bulkhead making sure to keep notes of the key measurements and parts that needed to be replaced within the bulkhead.
Once all the parts had been recreated, we took on the labor intensive task of putting it back together making sure we kept looking back at the key measurements to make sure we maintained the accuracy.
Once the bulkhead was fully rebuilt, we returned it to the customer to head off to be galvenised.
We had this project come in as a nearly entirely rusted bulkhead. This was a lengthy project that required careful attention to detail.
The customer came to us asking us to repair their bulkhead and sent photos. It was the worst bulkhead we have seen.
The bulkhead had been shot blasted leaving behind no foot wells and no A pillars.
The Front panel was completely rotten and the internal stiffening also needed completely replacing.
We bought the foot wells off the shelf as period correct items to replace the missing ones.
We also purchased a set of upper corner repair panels and A pillars however these both needed major modifications to make them correct.
The rest of the parts on the bulkhead were reverse engineered, modelled in CAD and then cut out on the plasma machine. Once the parts were cut out, we bent them to shape on the pressbrake.