Figure 1: Front of B-Bulkhead assembly
Figure 2: Rear of B-Bulkhead assembly
Materials
· 8 Square-headed Wood Screws
· Side Mount
· Four 7/16” bolts with nuts
· One 8-foot 2x4
Equipment
· Circular Saw
· Drill
· 7/16” drill bit
· Square-head drill bit
· Four C-clamps
· Two Pipe-clamps
This assembly plan includes instructions for one side of the B-Bulkhead. The same should be done on each side. Each bulkhead does not need to be installed at the same time, but if they are to be installed simultaneously, extra holding jigs and 2x4 pieces of wood will have to be cut. One side mount is required per side. Once everything is installed and all clamps are tight and in place, let dry and them remove all jigs carefully.
Holding Jig
The purpose of the holding jig, seen in Figure 2, is to make the bulkhead installation easier, so that it can be done by one person. Quickly assembling two of these jigs out of 2x4s and wood screws will easily hold the bulkhead upright in its place so that the upper clamping and sideways clamping can be done easily. Once the bulkhead is installed, the holding jig can be disassembled so that it does not get stuck in chassis. See steps below and Figure 3 for holding jig fabrication instructions. Two should be fabricated.
Cut three pieces of 2x4: 3 5/32”; 2 3/4”; 12 1/3” (these do no have to be exact as it is just a jig, but closer values will give best fit.)
Align two smaller pieces 1 9/16” in from the edges
Predrill 2 holes (two side-by-side) for wood screws over each red arrow
Drill in the wood screws
Place holder jig in chassis
Repeat until two holding jigs have been fabricated
Figure 3: Holding Jig Assembly
Side Mount
The side mount should be machined and installed so that structural adhesives can bond to the extra surface area that it provides, making the bulkhead more secure. Two holes should be drilled through the chassis. Line up the side mount centered on the chassis tube and 132.71mm from the T-Shaped connection (seen on the left in Figure 4). Mark and drill two 7/16” thru holes in the chassis. Insert 7/16” bolt from top for both holes and fasten them with a nut at the bottom. Grind off remaining bolt. High strength thread lock could be used for extra security or the nut could be welded to the bolt.
Figure 4: Side Mount Location
Figure 5: Side Mount Detail Drawing
Clamping
Structural adhesive is to be used in all clamping locations. A C-clamp will be used to fasten the bulkhead to the side mount, and a scrap piece of wood should be placed on the bulkhead to protect it and to distribute the clamping force. Clamping directions are shown with red arrows in Figures 6, 7, and 8. The straight 2x4s on the upper part of the bulkhead are each to be cut so they are 28.” If pipe clamps do not come with rubber protection on the end, place a piece of scrap wood between the pipe clamp and bulkhead for protection.
Figure 6: C-clamp mounting for upper part of bulkhead
Figure 7: Pipe clamp locations
Figure 8: Side mount clamping location