Starboard Bulkhead Replacement

[ToddL214]

I about to dig into a starboard bulkhead replacement project on my boat, (Catalina 310, Hull 018).

Does anyone have a photo of the bulkhead after the veneer has been removed or experience with such a project on their boat?

Thanks in advance for sharing what you have.

Sincerely,
Todd L.

 

[sailliny]

Are we talking about the bulkhead between the sitting area and the forward bed? If so, I have replaced my bulkhead.
The bulkhead did not have a "veneer"; it was plywood with a finished surface.

Attached is the bulkhead removed. It was a bit of a nightmare getting a replacement from Catalina. The first one they sent was not correct. They don't have the specs on our boat. The second picture is what they sent me, and as you can see, it would not fit. So I needed to ship them the bulkhead, and they did duplicate it for me. The final product, with some cutting, did fit.

Not sure what your question is, so if you could fill me in, maybe I can help.

 

[ToddL214]

Thank you for your reply and the photos; your timing is awesome as I'm emptying the boat now prior to starting this project.

From your photos, your issue appears to be the same as mine, (water from above), and your experience and the photos you've supplied are helpful. I'd be curious about the hull number of your boat to get an idea of how close its requirements/dimensions might be to mine. Is it correct that you ordered your replacement from the Catalina factory rather than Catalina Direct? I'm assuming the part was 3/4" marine plywood with teak veneer on both sides.

Given what you've shared about the piece being a single sheet, I feel like my bulkhead has delamination that will require at least a full replacement of the starboard side of the bulkhead. Do you recall any tricks or insights to dismantling the bulkhead that will help me out? I'm impressed at how clean the edge that was under your door frame is after being dismantled. Is it safe to assume you didn't run into any nasty epoxy or glue joints that you had to deal with?

Finally, can you confirm that you found a steel c-channel backer somewhere under the cedar closet in the VBerth like were used for the lower supports bow and stern of the chainplate?

Thanks again for your reply and assistance on my project.
Todd L.

 

[sailliny]

My boat is hull 67 2001. So, they should be very close to the same.

Yes, I was dealing with the Catalina Factory and not Catalina Direct.

Back in 2021 I was dealing with Lukas Serafin

Catalina Yachts – Parts Manager

7200 Bryan Dairy Road

Largo, Florida 33777

727-544-6681 x201

Lukas@catalinayachts.com

I believe it was ½” not ¾” but once you pull it you can check that. Yes, it was plywood with a teak veneer on both sides. I also had them stain and finish it. I didn’t feel I had the skill level to match the color.

FYI the cost at the time was about $700.00.

And yes, found a steel c-channel backer somewhere under the cedar closet in the Berth like were used for the lower supports bow and stern of the chainplate

Dismantling was an easy process with no epoxy. Once unbolted and screwed out slipped right out. The only real issue is getting it to fit, which required small trim cuts and filing until I fit.

I also did this on the hard with the mast down.

You also may want to order “welting” which is the flexible leather looking “molding” they use between the bulkhead and the ceiling and sides.

The actual project was easy. But dealing with Catalina was taxing at times.

Good luck with the project.

 

[Project_Mayhem]

I did this on another but not on a catalina. It's a pretty straightforward process. Nothing complicated. I think @sailliny's idea to add welting is an excellent one. It's like adding trim to hide the edge of flooring. It'll make a cleaner edge in less time than it would take to sand it smooth

 

[dlochner]

In case you haven't heard, Catalina Yachts is no longer in business. All of the assets were auctioned off in June or July.

Carefully remove the existing bulkhead so you can use it as a template. It will probably be difficult if not impossible to find plywood with the same veneer. Look for a company that specializes in exotic woods like M L Condon they may have an acceptable substitute.

 

[JRacer]

Advantage Lumber may be another option for exotic woods/veneers.

 

[Indysailor]

I didn't have the option to order a fabricated bulkhead when I removed and replaced both a on a different make/model several years ago, but this sounds like a very similar project. For mine, I sourced a sheet of okoume BS 1088 marine plywood, then I used the old ones as patterns to cut the new ones. This was less expensive and since I was cutting sheets to the exact specs, they fit perfectly on the first try. My guess is Catalina had a pattern for the bulkheads, but that each one may have needed a little trim to fit.

There's an album in my profile if you want to see what the finished wood looks like. Okoume grain is similar to mahogany. I stained it, epoxied the edges.

 

[shemandr]

I was going to recommend ML Condon for a question about plank material on another thread. But I wasn't sure if they were still operating. It's good to see they are. But now their warehouse is in Stormville instead of White Plains.
I've made several trips across the Throgs Neck Bridge with boards strapped to the top of my car.

 

[BigEasy]

There's an album in my profile if you want to see what the finished wood looks like. Okoume grain is similar to mahogany. I stained it, epoxied the edges.

Very nice results!

 

[sailliny]

If you go with doing it yourself, you may want to contact this company. At the time I was doing my research, they supplied Catalina with the stains they used.

Target Coatings | WaterBased Wood Finishes and Coatings

Water-based wood finish pros trust Target Coatings for quality and high-end results. Ultra-low VOC, HAPS-free water-based coatings and finishes since 1988.

www.targetcoatings.com