Problem: Bilco Ultra Series polymer basement bulkhead doors are NOT the same size as their metal counterparts (despite strenuous advertisement that they are a direct replacement)
Half-cocked solution: Install bulkhead over existing slab, seal in place where possible, and fit patio bricks under the overhanging 6" ...
Not good.
Correct plan: New concrete!
I decided I wanted to do this correctly, which meant installing anchor bolts to link old and new, and cutting down the old slab cap so that there would be no seam for water to penetrate.
Diamond masonry wheel for my angle grinder, I love you.
Regrettably, I forgot one of the most basic rules of drilling holes: ALWAYS buy 2 of every bit... that one came back and bit me. Oh well.
I got the holes drilled, trimmed the cap and set the bolts. Cutting the cap like this, and then breaking off the cut sections with a hammer, also leaves a nice coarse surface for the new concrete to bond to.
Next step: Pour some concrete! I chose to use a ready mix concrete pre-package for ease of mixing, and better strength (since I was not using rebar) over straight cement. And because I had to haul the materials on a 3 hour drive in my car, which is no good for loose aggregate.
I figured I would need 150lbs, so I bought 200lbs and got precisely this far:
Figures.
So off to the hardware store during that critical window before my first batch kicks, and after adding another 160lbs of concrete mix, here we are:
I was lazy and used the tuck-pointing trowel I already had to semi neaten things up, rather than buying the correct tool for this.
And here's where I left the project:
Next time around, I will dress up the concrete surface a bit using a coarse sanding wheel / masonry grinding disk, for aesthetic purposes. Then, since the cement has had a few weeks to cure, I can seal the polymer bulkhead panels in place, and then make sure the aluminum cross-tie/sill fits in place and install the concrete anchors for that, then seal it in place as well.
One more project down that I needed to do before winter. Many more to come.