I have installed both bulkheads. The full size one behind the bow cockpit is sealed in with Lexel so it should be watertight. The one in front of the stern cockpit is almost full size and is a friction fit only. It is only used during transportation and storage to provide additional hull rigidity. It has to be removed so that the stern paddler can reach the foot pegs/rudder control.
For those folks that don’t have experience, I will provide a brief overview.
First I made a bulkhead pattern, from the outside of the kayak using a ruler and cardboard. Making it in several parts and then taping the parts together is the easiest method. Here is the final pattern (half of a kayak.)
If you look carefully you can see I made the pattern in three parts (top, side and bottom) and then taped them to each other. After you assembly the parts try the pattern on the kayak (both sides) to make sure it fits.
Then I cut a inside pattern out of cardboard. I made this one smaller by the (assumed) thickness of the hull material. Here is that pattern.
This pattern is used to double check that the bulkhead will actually fit where you want to install it. Some people would say this is overkill, but cardboard is cheap. If this pattern does not fit properly you can adjust it as needed. For example the hull material may be a different thickness than you assumed, especially where the hull meets the deck.
Once you have the final pattern you can cut the foam bulkhead. Since the foam will compress somewhat and your cut may not be exact, I suggest that you cut the bulkhead a little bigger than your final inside pattern. Test your foam to see how much it will compress to help decide how much tolerance you have. You can cut the foam with a sharp kitchen knife.
I bought 2 inch thick foam from:
2" thick Closed cell foam (kayakoutfitting.com)
But there are many other places you can get similar products.
I purchased the Lexel from Lowe’s, they had it in stock. Home Depot did not have it. Here is a link:
Lexel 5-fl oz Clear Paintable Solvent Caulk in the Caulk department at Lowes.com
In the center hatch I inserted a partially inflated yoga ball to provide floatation and water displacement if the kayak capsizes or otherwise takes on water. The yoga ball only cost $2.50, so it was by far the cheapest option. Here is a picture of the yoga ball installed.
I was really glad I had installed my hoist system, since it made it easier to apply the Lexel to the top of the bulkhead. I just flipped the kayak over and hauled it up to shoulder level. Then I was able to stand up straight (important for us older folks) with my head and arms inside the kayak to apply the Lexel. In addition to the hoist I used some additional straps for security. Here is a picture.
Anyway, for all of you people that are new to this, like I am, don’t be afraid to try. It was not hard to do, just take your time and remember always measure twice, cut once.
I had not used it, so I thought I did not need it. Since then I have had several times that I wished I still had it. Isn’t that the way things go!