Fillet or filet?

We are now preparing to install the three bulkheads.  We vacuum bagged the fitted bulkheads to make a very high quality lamination.

Here you can see the fillets made from a putty of epoxy and microballoons.  If you recall the last time we attempted this, I did the filleting with mixed success.  This time I handed over the task to the "Epoxy Master."  And sure enough, she's a natural at this.  This time we started by filleting all three bulkheads in place and then let the epoxy start to set before taping with 4" biaxial glass.  This made the process go much smoother.

A good mix for putty that does not sag is 1/4 cup balloons for every 25 ml epoxy mix.  You have to add the balloons slowly to mix smoothly and avoid turning the balloons into a dust storm.  Don't even think about doing this without a decent dust mask or respirator.  The balloons tend to get electrically charged and are very small (hence the name "micro" balloons).  The slightest disturbance tends to send them airborne.  In any case, this mix makes a very dry putty that can be molded by hand and doesn't slump.

Here you can see one of the jigs I made to hold the bulkhead in position during installation.  It is critical that the cutout for the beam be positioned correctly.  The reference marks in the top photo are only barely visible, so trust me, I very carefully laid out the jigs so I could attach the bulkhead in the correct position to within a millimeter.  We'll see if I met the goal in a few months when we install the beams.  I made a jig for each bulkhead.  We  leave the jig on until the first layer of glass tape is applied.  Note the cuts in the jig to allow access around the entire join.