B-Bulkhead Assembly Plan

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Materials

·        8 Square-headed Wood Screws

·        Side Mount

·        Four M8 x 1.25mm bolts with nuts, each 50mm long

·        One 8-foot 2x4

Equipment

·        Circular Saw

·        Drill

·        8.80mm drill bit (for standard fit)

·        Square-head drill bit

·        Four C-clamps

·        Two Pipe-clamps

This assembly plan includes instructions for one side of the B-Bulkhead. This assembly should be done twice, so that there is a mounting method for each side. 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.

1. Cut three pieces of 2x4: 3 5/32”; 2 3/4”; 12 1/3” (this is just a rough estimate based on current chassis model. Take new measurements during assembly process.)

2. Align two smaller pieces 1 9/16” in from the edges of the larger piece

3. Predrill 2 holes (two side-by-side) for wood screws over each red arrow

4. Drill in the wood screws

5. Place holder jig in chassis

6. Repeat until two holding jigs have been fabricated

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. Line up the side mount centered on the chassis tube and approximately 70.3mm from the T-Shaped connection (seen on the left in Figure 4). Mark and drill one 8.80mm thru holes in the chassis, and also cut a 8.80mm radius and 30mm long slot in the chassis. This will allow for adjustability. Insert M8 bolt from top for both holes and fasten them with a nut at the bottom. Grind off remaining bolt is any is leftover. High strength thread lock could be used for extra security, or the nut could be welded to the bolt.

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.