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Thin Bulkhead Bonding

When laying a plywood skin over a thin ply bulkhead without edge framing, there is a danger of pushing out the little epoxy that will be there and ending up with little or no bond strength.

To avoid that risk, I like to well bevel the edges of the bulkhead, to that there's space on each side of the central line of contact for the thickened epoxy to remain. Once cured, one can then paste in a good rounded fillet of epoxy on either side and the joint will then become much stronger, with the centre of the bulkhead ply, well locked into the cured epoxy.

Typically, a bias tape is later laid over the concave fillet on each side.

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