Wednesday, November 24, 2010

Epoxying the butt seams


We kept the epoxy and hardener in our house and when we brought it over to use it we kept it in front of a warm lamp to keep it from getting too cold. We mixed the epoxy in small plastic juice cups (we used a new one each epoxying session).

We mixed the epoxy under the warm light as advised in the manual if working in cold conditions. I did inside of the left side first and we each did just one seam at a time. We put plastic wrap under each seam and weighted down each panel with random objects. The first seams we did were really messy, so we learned that you should just coat the panels with epoxy, put the light fiberglass tape down, paint a little more epoxy until all the tape becomes clear. Then you don't need to go crazy with epoxy on top of that but put a nice dollop on and spread it out a bit.

Then place the plastic mylar down and push all the bubbles out and press the plastic down so that all of the epoxy is in contact with the mylar sheet.

Then we put the section of 2x4 on top of the plastic making sure that none of it is touching the panel.
Then place weights (we used two bricks wrapped in plastic per seam) on top of the 2x4. The plastic/2x4/bricks will float a little bit, I just pressed it down and waited till it stopped moving. Then go back and clean up all the epoxy that was squeezed out with the squeegee. It makes sanding and filing much easier if you do this part well. If your 2x4 doesn't cover all of the plastic, I found pressing the squeegee down on the edges of the plastic to squeeze out the rest so that when it cures it is all as even as possible.

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