Now at the point where we are putting everything back together....thanks for all you help to get us this far!
Now for the wallboard:
What have you found is the best method of cutting wallboard?
Was thinking a Stanley knife, as maybe a jigsaw will chip the edge????
Stanley knife. 3 cuts with a good blade should cut it. Do not skimp on blades, change it as soon as it goes dull. They are not that expensive and a good blade gives a clean cut with less effort and less chance of slipping.
Shouldn't need the tape then to get a clean cut. I used a number of blades and made all my cuts with a steel straight edge. Light pressure on the first run so as not to go off line then you can apply a little more for 2nd and 3rd cut.
Have you given it a reality check with a hose on the outside? I did a boat repair once on a balsa cored hull and was just about to bond in the inner skin, when it started to rain and water appeared between the skins. There was a second leak from a place I'd never dreamed could be connected. Had to dry it all out again, but was so pleased I hadn't bonded it up before fixing the second leak!
not yet - that's the plan for this weekend. Defo not putting the board on until tried and tested. Also waiting for it to be a dry day as seen a couple of holidays in the Sika that I want going over again, just to make sure.