from an efficiency standpoint, is it better to lay up (or vacuum bag) large sheets of bulkhead and then cut to fit, or mold each piece individually?
Structurally, would this method be as strong (since you're sawing up the stuff after curing) as molding each piece individually?
It just seems that if you designed a large piece scribed with all the smaller sections on it (like a puzzle), you'd only have to do all the bagging once, and then get a tiny band saw to cut the rough shapes for all the bulkheads.
Shouldn't be any structural disadvantage to doing it in one solid sheet and then cutting. However, the way the Man Shed is doing it is easier to get a good fit. The foam is very easy to sand/whittle into a great fit. After you cover it with cloth, then you just cut away the cloth from the edges of the fitted foam and you're good to go.
