All the bulkheads and parts start off by being drawn on CAD, this ensures everything is as accurate as possible and gives us accurate measurements for cross reference. We produce our parts from laser cut steel which is then folded and formed to the correct shape. This includes the various hidden strenghteners, and the finished bulkhead would be difficult to distinguish from an original.
Before assembly all internal parts are spray painted with a weld through primer to ensure that no part of the bulkhead in unpainted. We discuss the several finish options in the finishing section.