Why did Dagger switch from 3" foam bulkheads to 2" Synergy® foam?

Polyethylene foam is 100% recyclable.
Unlike cross-linked foams, the Synergy® foam does not out gas, which results in fewer bubbles in the sealant.
Bulkheads are cut on a water jet machining system resulting in accurate, consistent shapes based on CAD data.
Two ½” deep routed slots on the hatch side of the bulkhead allow the foam to be compressed in place resulting in a tight fit between the hull and bulkhead.
¼” beveled edge on both sides of the bulkhead create more surface area for the sealant to bond with the foam and hull.

75 bulkheads were pull tested with the results showing a 38% increase in pull strength over the existing 3” cross-linked foam
After a mere 4 days of cure time, a sample boat was paddled in off-shore conditions and car topped for over 1,000 miles with no signs of separation in the sealant.

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