Expedition Evans · video

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The crew of the 45-ft sailboat Eva discovers a structural failure in a half-bulkhead beneath their master cabin bed.1:39 The original bond between the bulkhead and the hull has cracked, likely due to stress from slamming or twisting in heavy seas.1:51 Inspection reveals the factory bond was applied directly to unscuffed gel coat, preventing a proper mechanical connection.2:46 To repair the bulkhead, the crew sands the gel coat to create a textured surface, applies TotalBoat Thixo to fill gaps and create a radius, and tabs the bulkhead to the hull using biaxial fiberglass cloth.17:02 They prepare the fiberglass off-site by pre-impregnating it with epoxy and covering it with peel ply to minimize sanding and mess during installation.14:41 The repair restores structural rigidity to the hull skeleton.10:28 Proper surface preparation and tabbing are essential for maintaining the structural integrity of internal boat components.

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