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Rob's REBVAIR Project
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Date:  3-12-2020
Number of Hours:  1.00
Manual Reference:  
Brief Description:  Baggage bulkhead Part 5

Image 1 shows the small flange holding the top corners. Images 2 and 3 show the part covered with headliner fabric. Final weight is 2 lbs 12 oz.

Despite having started with a $15 piece of foam from Lowes, this composite bulkhead is not exactly inexpensive when you factor in the epoxy and glass fabric (I used 3 yards of fabric, and about 1 quart total of 2-part epoxy - though much less than that stayed on the part). In my case these were just lying around from my previous project. But, just roughly comparing things, composite construction is not nearly as 'green' as aluminum. There is a lot of wasted epoxy and glass fabric, peelply, plastic sheeting. At least aluminum off-cuts are either reuseable as scrap, and/or recyclable.

All told, I do like the finished bulkhead, and it's likely to do a great job with noise and heat insulation. But I think Roger's design is probably superior for sheer durability. An all-aluminum divider will take a lot of punishment, which is desireable if you want to throw equipment or folding bikes in the baggage compartment in a care-free manner. With the headliner cover, small dents won't even show up. And with the right number of stiffening flanges to use as 'seams', you could make it with left over aluminum sheet from the airplane build (i.e. you don't need a full 4x4 sheet).

My bulkhead was a bit of an experiment, and is fit-for-purpose until I decide to fabricate something better.
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upper attach point

upper attach point

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finished bulkhead

finished bulkhead

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