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Andy replaces structural bulkheads by first creating templates from OSB before cutting the final panels from Coosa board.3:05 To ensure a precise fit without creating hard spots against the hull, he cuts the templates with a slight gap, aiming for a fit that slides into position without requiring force.3:53 He uses a laser level to ensure the new bulkheads are plumb and square, which simplifies the future installation of a door frame.16:01 When transferring the template shapes to the expensive Coosa panels, he aligns the straight edges with the factory edge of the material to maintain structural integrity and minimize waste.13:34 He notes that while the bulkheads should touch the hull for support, they must not be wedged in, as forced contact creates localized stress points.4:12 The process involves iterative trimming and fitting until the panels achieve a tolerance within 1/16th of an inch.16:29

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