DIY Bulkhead Replacement

With $400 in materials cost and your DIY know-how, learn how to get rid of your rotting bulkhead and replace it with a fresh one.

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After removing a rotted out bulkhead on this 1978 O'Day 23, the author replaced it with new marine plywood with a white oak surface. (Photo/ Steve Milan)
After removing a rotted out bulkhead on this 1978 O'Day 23, the author replaced it with new, white-oak finished marine plywood. After removing a rotted out bulkhead on this 1978 O'Day 23, the author replaced it with new marine plywood with a white oak surface. (Photo/ Steve Milan)

Many of the fiberglass sailboats constructed during the 1970s and 1980s are still in existence, though often in varying states of disrepair. These vessels can be acquired inexpensively and restored with minimal cost but significant effort. I am nearing completion of an extensive restoration of a 1978 O’Day 23. If you’re considering restoring an older boat, you may likely discover weaknesses in the bulkheads. Chainplates often leak, and when anchored to a wooden bulkhead, rot, mold and mildew are common. Since bulkheads are crucial for providing structural integrity and support to the hull and deck of a boat, repairing or replacing them is essential.

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After graduating with a Masters degree in Engineering, Steve Milan bought a Sunflower and kept it in his living room. Since then he has owned a dozen boats, in the Chesapeake, Lake Pontchartrain, the Gulf, and the NC coast. His largest boat was a C&C Landfall 38. The most famous is a Raider Cherubini 33, hull #1. After retiring from a colorful career, he formed a nonprofit dedicated to restoring old sailboats.

4 COMMENTS

  1. Good point nfgjr1. Not ideal, undoubtedly cost-driven, but it worked for many years. Many small boats of this era have only a partial bulkhead. It’s a small boat, and I think they were counting on the heavy hull liner for rigidity. The compression post carries the mast loading. The bulkhead does carry the chainplate loading – it seems plenty strong, and would probably have been OK except for the poor chainplate seal causing leaks and rot.

  2. A missed opportunity to upgrade the bulkhead. But I suspect the rest of the boat is of modest quality as well.

    I would not consider this boat to be a safe vessel for where I sail in summer, Flathead Lake, Montana. I have upgraded my Cape Dory Typhoon for the lake.

    In winter I have an old Baba 40 and I try to be in the Bahamas. It’s pretty bullet proof.

  3. Casey, thanks for your opinions on sailboat design. All of the boats I owned had pros and cons. The O’Day is an affordable trailer sailor that sleeps 4, with a full galley and head.

    When I started this project, i set out to restore everything to original condition. As the project progressed, i began upgrading to modern components and systems.

    Just curious – how would you have changed the bulkhead design?