WEST SYSTEM User Manual (Part 1)
Contents
1. User Manual 05 HARDENER Product Guide 002 950 WEST SYS TEAM User Manual Product Guide West System Epoxy is a versatile high quality two part epoxy that is easily modified for a wide range of coating and adhesive applications It is used for construction and repairs requiring superior mois ture resistance and high strength It bonds to fiber glass wood metal plastics fabrics and other composite materials and is especially suited for ma rine applications This manual is designed to help you become familiar with WEST SYSTEM products and use them effectively e The User Manual provides information about safety handling and the basic techniques of epoxy use Understanding these basic techniques will al low you to tailor WEST SYSTEM products to your ex act repair and construction needs These techniques are used in a wide range of repair and building procedures such as those described in de tail in WEST SYSTEM instructional publications and DVD s page 19 e The Problem Solver will help you identify and pre vent potential problems associated with using epoxy e The Product Guide gives you complete descrip tions of WEST SYSTEM products including selection and coverage guides to help you choose the most appropriate products and product sizes for your project WEST SYSTEM products are available from quality marine chand leries and hardware outlets in many areas For the name of the WE2. ener Pump one full pump stroke of resin for each one full pump stroke of hardener Depress each pump head fully and allow the head to come completely back to the top before beginning the next stroke Partial strokes will give the wrong ratio Read the pump instructions before using pumps Before you use the first mixture on a project verify the correct ratio according to the in structions that come with the pumps Recheck the ratio anytime you experience problems with curing Dispensing without Mini Pumps Weight volume measure To measure 105 Resin and 205 or 206 Hardener by weight or volume combine 5 parts resin with 1 part hardener To measure 105 Resin and 207 or 209 Hardener by volume combine 3 parts resin with 1 part hardener by weight combine 3 5 parts resin with 1 part hardener First time users If this is the first time you have used WEST SYSTEM epoxy begin with a small test batch to get the feel for the mixing and curing process before applying the mixture to your project This will demonstrate the hardener s open time for the temperature you are working in and assure you that the resin hardener ratio is metered properly Mix small batches until you are confident of the mixture s handling characteristics Mixing Stir the two ingredients together thoroughly at least 1 minute longer in cooler tempera tures Figure 3 To assure thorough mixing scrape the sides and bottom of the pot as you mix Use the flat end of
3. num Etch Kit before oxidation occurs Follow kit directions Use G flex epoxy especially on flexible pieces Polyester fiberglass Clean contamination with a silicone and wax remover such as DuPont Prep Sol 3919S Sand with 80 grit paper to a dull finish Plastic Clean plastics except for polycarbonate with isopropyl alcohol to remove con tamination Sand all plastics including polycarbonate with 80 grit sandpaper to provide texture for good adhesion Flame treat Pass the flame of a propane torch across the surface quicky about 12 inches per second ABS and PVC for additional benefit HDPE high density polyethylene and LDPE low density polyethylene must be flame treated for good adhesion Use G flex epoxy for plastics See page 16 m WEST SYSTEM User Manual amp Product Guide User Manual Bonding gluing l This section refers to two types of structural bonding Two step bonding is the preferred method for most situations because it promotes maximum epoxy penetration into the bonding surface and prevents resin starved joints Single step bonding can be used when joints have minimal loads and excess absorption into porous surfaces is not a problem In both cases epoxy bonds best when it is worked into the surface with a roller or brush Before mixing epoxy check all parts to be bonded for proper fit and surface preparation Surface preparation page 6 gather all the clamps and tools necessary for the operation and cov
4. you shape it into a fillet For larger fillets add thickened mixture to the joint as soon as the bonding operation is complete before the bonding mixture becomes tack free or any time after the final cure and sanding of exposed epoxy in the fillet area 1 Bond parts as described in Bonding page 7 2 Shape and smooth the squeezed out thick epoxy into a fillet by drawing a rounded filleting tool mixing stick along the joint dragging excess material ahead of the tool and leaving a smooth cove shaped fillet bordered on each side by a clean margin Some excess filleting material will remain outside of the margin Figure 13 Use the excess ma terial to refill any voids Smooth the fillet until you are satisfied with its appearance A mixing stick will leave a fillet with about a 3 radius For larger fillets an 808 Plastic Spreader cut to shape or bent to the desired radius works well Apply additional thickened epoxy to fill voids or make larger fillets Apply the mixture along the joint line with the rounded mixing stick using enough mixture to create the desired size of fillet For longer or multiple fillets empty caulking gun cartridges or dis posable cake decorating bags can be used Cut the plastic tip to lay a bead of thickened epoxy large enough for the desired fillet size Heavy duty sealable food storage bags with one corner cut off may also be used 3 Clean up the remaining excess material outside of the margin by using a mixin
5. Data Sheet KEEP RESINS HARDENERS FILLERS AND SOLVENTS OUT OF THE REACH OF CHILDREN For additional safety information or data visit www westsystem com or write to EPOXY SAFETY Gougeon Brothers Inc P O Box 908 Bay City MI 48707 USA E Contain large spills with sand clay or other inert absorbent material Use a scraper to contain small spills and collect as much material as possible Follow up with absorbent towels Uncontaminated resin or hardener may be reclaimed for use DO NOT use sawdust or other fine cellu lose materials to absorb hardeners DO NOT dispose of hardener in trash containing sawdust or other fine cellu lose materials spontaneous combus tion can occur 2 WEST SYSTEM User Manual amp Product Guide Clean resin or mixed epoxy residue with lacquer thinner acetone or alcohol Fol low all safety warnings on solvent con tainers Clean hardener residue with warm soapy water Dispose of resin hardener and empty containers safely Puncture a corner of the can and drain residue into the appro priate new container of resin or hardener DO NOT dispose of resin or hardener in a liquid state Waste resin and hardener can be mixed and cured in small quanti ties to a non hazardous inert solid A WARNING Large pots of curing epoxy can get hot enough to ignite surrounding combustible materials and give off hazardous fumes Place pots of mixed epoxy in a safe and ventilated area away from workers
6. and combusti ble materials Dispose of the solid mass only when cure is complete and the mass has cooled Follow federal state or local disposal regulations E User Manual Epoxy chemistry Epoxy s cure stages Mixing 105 Epoxy Resin with a hardener begins a chemical reaction that transforms the combined liquid ingredients to a solid This period of transformation is the cure time As it cures epoxy passes from the liquid state through a gel state before it reaches a solid state Figure 1 Liquid Open time Open time also working time or wet lay up time is the portion of the cure time after mixing that the resin hardener mixture remains a liquid and is workable and suitable for application All assembly and clamping should take place during the open time to assure a dependable bond Gel Initial cure phase The mixture passes into an initial cure phase also called the green stage when it begins to gel or kick off The epoxy is no longer workable and will progress from a tacky gel consistency to the firm ness of hard rubber which you will be will be able to dent with your thumbnail The mixture will become tack free about midway through the initial cure phase While it is still tacky about like masking tape a new ap plication of epoxy will still chemi cally link with it so you may still bond to or recoat the surface with out special preparation However this ability diminishes as
7. best adhesion and load transfer the joint s bonding surfaces must be properly prepared JOINT AREA The bonding area of the joint must be adequate for the load on the joint and materials being joined Increased over lap scarf joints fillets and reinforcing fibers can be used to increase joint bonding area Laminating The term laminating refers to the process of bonding numbers of relatively thin layers like plywood veneers fabrics or core material to create a composite A composite may be any number of layers of the same material or combinations of different materials Methods of epoxy application and clamping will differ depending on what you are laminating Because of large surface areas and limitations of wet lay up time roller application is the most common method for applying epoxy A faster method for large surfaces is to simply pour the resin hardener mixture onto the middle of the panel and spread the mixture evenly over the surface with a plastic spreader Apply thickened mixtures with an 809 Notched Spreader Using staples or screws is the most common method of clamping when you laminate a solid material to a solid substrate An even distribution of weights will work when you are lami nating a solid material to a base that will not hold staples or screws such as a foam or honey comb core material Vacuum bagging is a specialized clamping method for laminating a wide range of materials Through the use of a v
8. enough filler to completely bridge gaps between surfaces without sagging or running out of the joint or gap A small amount should squeeze out of joints when clamped For thick mixtures don t fill the mixing cup more than 1 3 full of ep oxy before adding filler When making fairing compounds stir in as much 407 or 410 as you can blend in smoothly for easy sanding the thicker the better Be sure all of the filler is thoroughly blended before the mixture is applied Figure 5 Stir in small handfuls of filler until the desired consistency is reached Spread the mixture into a thinner layer either around the inside of the mixing cup or ontoa flat non porous surface or palette to extend its working life Additives Additives are used to give epoxy additional physical properties when used as a coating Al though additives are blended with mixed epoxy in the same two step process as fillers they are not designed to thicken the epoxy Refer to the Additive descriptions on page 23 Fol low the mixing instructions on the individual additive containers E Removing epoxy Removing uncured or non curing epoxy Uncured epoxy is removed as you would spilled resin Scrape as much material as you can from the surface using a stiff metal or plastic scraper warm the epoxy to lower its viscosity Clean the residue with lacquer thinner acetone or alcohol Follow safety warnings on solvents and provide adequate ventilation Allow solvents t
9. hardener cure speed and epoxy temperature 1 Hardener cure speed Each hardener has an ideal temperature cure range At any given temperature each resin hardener combination will go through the same cure stages but at different rates Se lect the hardener that gives you adequate working time for the job you are doing at the tem perature and conditions you are working under The Hardener Selection Guide page 21 and container labels describe hardener pot lives and cure times Pot life is a term used to compare the cure speeds of different hardeners It is the amount of time a specific mass of mixed resin and hardener remains a liquid at a specific temperature a 100g mass mixture in a standard container at 72 F Because pot life is a measure of the cure speed of a specific contained mass volume of epoxy rather than a thin film a hard ener s pot life is much shorter than its open time 2 Epoxy temperature The warmer the temperature of curing epoxy the faster it cures Figure 1 The tempera ture of curing epoxy is determined by the ambient temperature plus the exothermic heat generated by its cure Ambient temperature is the temperature of the air or material in contact with the epoxy Air temperature is most often the ambient temperature unless the epoxy is applied to a surface with a different temperature Generally epoxy cures faster when the air temperature is warmer Exothermic heat is produced by the chemical reaction tha
10. texture for epoxy to key into Primary secondary bonding Primary bonding relies on the chemical link ing of adhesive layers such as the wet lay up of fiberglass laminate in a mold All the lay ers of adhesive cure together in a single fused layer Epoxy applied over partially cured epoxy will chemically link with it and is considered a primary bond The ability to chemically link diminishes as the previous layer of epoxy cures You must then prepare the cured surface for a secondary bond Secondary bonding relies on mechanical rather than chemical linking of an adhesive to a material or cured epoxy surface The ad hesive must key into pores or scratches in the surface a microscopic version of a dovetail joint Proper surface preparation provides a texture that will help link the cured epoxy to the surface Except for bond ing to uncured or partially cured epoxy sur faces all epoxy bonds are secondary bonds Whether you are bonding fairing or applying fabrics the success of the application de pends not only on the strength of the epoxy but also on how well the epoxy adheres to the surface to which it is being applied Unless you are bonding to partially cured epoxy the strength of the bond relies on the epoxy s ability to mechanically key into the surface That is why the following three steps of surface preparation are a critical part of any second ary bonding operation For good adhesion bonding surfac
11. the topmost trim ming lift the opposite cut edge to re move the overlapped trimming A variation of this method is to apply the fabric after a wet out coat has cured thoroughly and the surface has been prepared for bonding This method assures a thorough wet out of the substrate and fabric and the fabric can still be positioned easily while it is being wet out Wet method An alternative is to apply the fabric or tape to a surface coated with wet epoxy As men tioned this is not the preferred method especially with large pieces of cloth because of the difficulty removing wrinkles or adjusting the position of the cloth as it is being wet out However you may come across situations such as applying fabric on vertical or overhead surfaces when this method may be useful or necessary 1 Prepare the surface for bonding Surface preparation page 6 Pre fit and trim the cloth to size Roll the cloth neatly so that it may be conveniently rolled back into position later 2 Roll a heavy coat of epoxy on the surface 3 Unroll the glass cloth over the wet epoxy and position it Surface tension will hold most Figure 29 Coat the surface to fill the weave before the wet out becomes tack free Clear wood finishes For stripper canoes etc An alternative wet out method is to lay the epoxy onto the fabric with a short bristled brush Dip the brush in the epoxy and lay the epoxy onto the surface with a light even stroke Don t forc
12. 100 grit is usually sufficient 120 180 grit may be adequate for primers and high solids coatings Finishing with 220 400 grit paper will result in a high gloss finish for most paints or varnishes Grits finer than this may not provide enough tooth for good adhesion Wet sanding is preferred by many people because it reduces sanding dust and it will allow you to skip Step 2 4 After you are satisfied with the texture and fairness of the surface rinse the surface with fresh water Figure 33 Rinse water should sheet evenly without beading or fish eyeing If rinse water beads up a sign of contamination wipe the area with solvent and dry with a paper towel then wet sand again until beading is eliminated Proceed with your final coating after the surface has dried thoroughly To reduce the possibility of contamination it is a good idea to begin coating within 24 hours of the fi nal sanding Follow all of the instructions from the coating system s manufacturer A good trick used by professionals is to make a test panel to evaluate the degree of surface preparation required and the compatibility of the finish system E Finish coatings Coating function A finish coating paint or var nish over an epoxy barrier coat protects the epoxy from sunlight as well as decorating the surface In do ing so the finish coating extends the life of the epoxy moisture barrier which in turn provides a stable base that extends the life of the finis
13. Figure 22 Remove any excess thickened epoxy be fore it cures If the voids you are filling are over 1 2 deep apply the mixture in several ap plications or use 206 Slow Hardener or 209 Extra Slow Hardener depending on ambient temperature Note On vertical and overhead surfaces allow the wet out coat to gel before applying fairing compound The fairing compound may sag or slide off the fresh wet out coat Apply the fairing compound while the wet out is still tacky Allow the final thickened epoxy application to cure thoroughly 6 Sand the fairing material to blend with the surrounding contour Figure 23 Begin with 50 grit sandpaper if you have a lot of fairing material to remove Use 80 grit paper on the appropriate sanding block when you are close to the final contour CAUTION Don t forget your dust mask Remove the sanding dust and fill any remain ing voids following the same procedure 7 Apply several coats of resin hardener to the area with a disposable brush or roller after you are satisfied with the fairness Allow the final coat to cure thoroughly before final sanding and finishing Note 410 Microlight filler can be affected by the solvents in most paints Surfaces faired with with 410 filler must be sealed with epoxy before applying any solvented paints W Figure 24 Spread the epoxy over the cloth surface with a plastic spreader ee 2 med A i J Figure 25 Squeegee away excess ep oxy before it begins to ge
14. ST SYSTEM products dealer nearest you or for additional techni cal product or safety information contact Gougeon Brothers Inc or visit our website Why WEST SYSTEM Epoxy All epoxies are not created equal Epoxy brands can vary widely in their formulations quality of raw materials and their suitability for marine en vironments It s easy to market an off the shelf industrial epoxy product as a marine epoxy or formulate an epoxy with one or two favorable char acteristics while sacrificing other important characteristics It s much more difficult balancing all of the physical and mechanical proper ties necessary for a versatile Safety Toughness high quality marine epoxy Defining an epoxy s per formance criteria and designing a formula to meet those criteria re Strength Fatigue resistance Moisture resistance EPOXY Thermal di PERFORMANCE properties quires good chemistry rigorous test programs skillful shop work anddi Handling amp Creep rect experience with to Paree RUCA resistance day s high performance boats Flexibility Cost and other composite structures Reliability and performance WEST SYSTEM epoxy was created by Gougeon Brothers sailors builders and formulators who know the engineering and the chemistry required for high performance composite structures We have maintained that performance driven development of marine epoxies since the company was founded in 1969 contin
15. acuum pump and plastic sheeting the atmosphere is used to apply perfectly even clamping pressure over all areas of a panel regardless of the size shape or number of layers For detail information on vacuum bagging refer to 002 150 Vacuum Bag ging Techniques M WEST SYSTEM User Manual amp Product Guide 7 User Manual Bonding with fillets Figure 13 Shape and smooth the fillet with a rounded filleting tool gt EER i i x Y a b pa nas I 5 g f ae i gt m Thy eh oO pa y RETS fi he A kN E k x 4 2 3 5 NI Figure 14 Clean up the excess epoxy outside of the fillet margin Wet out Pre coating porous surfaces with neat un thickened epoxy before applying a thick ened epoxy adhesive or fairing compound improves adhesion Neat epoxy penetrates and keys into surface pores and end grain better than thicker epoxy A fillet fil it is a cove shaped application of thickened epoxy that bridges an inside corner joint It is excellent for bonding parts because it increases the surface area of the bond and serves as a structural brace All joints that will be covered with fiberglass cloth will require a fillet to support the cloth at the inside corner of the joint The procedure for bonding with fillets is the same as normal bonding except that instead of removing the squeezed out thickened epoxy after the components are clamped in position
16. airing material not thick enough Fresh epoxy wet out won t sup port weight of fairing Epoxy not completely cured Paint incompatible with epoxy Epoxy surface not thoroughly prepared Batch too large or left in mixing pot too long Temperature too warm for the hardener Application too thick Air trapped in the material es capes through coating out gas sing as the material s temperature Is rising Surface tension causes epoxy film to pull away from pinhole before it gels Contamination of the coating or surface or improper abrasion for the coating Moisture in contact with hard ener and metal container Product Guide SOLUTION 1 Use 800 Roller Covers and roll the coating out into a thinner film A thin film will flow out much smoother than a thicker film after it is tipped off with the foam roller brush 2 Warm the epoxy to thin it or apply the coating at a warmer temperature See Epoxy barrier coating page 12 1 Apply the coating at a warmer temperature 2 Warm the resin and hardener before mixing to speed the cure in cool weather 3 Switch to a faster hardener if possible See Controlling cure time page 3 Add more filler to the mixture until it reaches a peanut butter consis tency the more filler added the stiffer and easier it will be to sand Allow the wet out coat to gel before applying the fairing material to verti cal surfaces See Fairing page 10 Allow the f
17. aning or joining Increase bonding area by adding fillets bonded fasteners or scarf joints Use just enough clamping pressure to squeeze a small amount of epoxy from the joint See Clamping note page 9 1 Apply moderate heat to partially cured coating to remove moisture and complete cure See out gassing caution page 4 2 Use 207 Hardener for clear coating applications and for bonding thin ve neers where epoxy may bleed through to the surface 1 Apply coating at warmer temperature epoxy is thinner at warmer tem peratures 2 Apply epoxy in thin coats 3 Apply moderate heat to release trapped air and complete cure See Caution top of page 4 1 Blush is water soluble Remove with water See Special prepara tion Cured epoxy page 6 2 Use 207 Special Clear Hardener 207 Hardener is blush free WEST SYSTEM User Manual amp Product Guide PROBLEM Runs or sags in coating Fairing compound epoxy 407 or 410 mixture sags and is difficult to sand Thick fairing compound epoxy 407 or 410 mixture sags Paint varnish or gelcoat will not set up over epoxy Epoxy became very hot and cured too quickly Bubbles formed in coating over po rous material bare wood or foam Pinholes appear in epoxy coating over abraded fiberglass or epoxy Fish eyeing in coating Hardener has turned red after sev eral years storage POSSIBLE CAUSES Epoxy applied too thickly Coating curing too slowly F
18. e a test panel to evaluate the degree of surface preparation required and the compatibility and handling characteristics of the finish system E WEST SYSTEM User Manual amp Product Guide 13 User Manual Problem solver This guide is designed to help identify and prevent potential problems you may encounter using WEST SYSTEM Epoxy If the solutions described here do not resolve the problem call the Gougeon Brothers technical staff 866 937 8797 PROBLEM The epoxy mixture has not cured after the recommended cure time has passed Bond failure Clear coating turned cloudy Waxy film appears on surface of cured epoxy 14 POSSIBLE CAUSES Off ratio too much or too little hardener will affect the cure time and thoroughness of the cure Low temperature epoxy mix tures cure slower at low tem peratures Insufficient mixing Incorrect products Insufficient cure Resin starved joint epoxy has wicked into porous surfaces leaving a void at the joint Contaminated bonding surface Bonding area too small for the load on the joint Too much clamping pressure squeezed epoxy out of the joint Moisture from condensation or very humid conditions reacts with components in uncured hardener Entrapped air from aggressive roller application Amine blush formation is a typi cal result of the curing process SOLUTION 1 Remove epoxy Do not apply additional material over non curing epoxy See Re
19. e removed It s a good idea to as sume it has formed on any cured epoxy surface To remove the blush wash the surface with clean water not solvent and an abrasive pad such as Scotch brite 7447 General Purpose Hand Pads Dry the surface with paper towels to remove the dissolved blush before it dries on the surface Sand any remaining glossy areas with 80 grit sandpaper Wet sanding will also remove the amine blush If a release fabric is applied over the surface of fresh epoxy amine blush will be removed when the release fab ric is peeled from the cured epoxy and no additional sanding is required Epoxy surfaces that are still tacky may be bonded to or coated with epoxy without washing or sanding Before applying coatings other than epoxy paints bottom paints varnishes gelcoats etc allow epoxy surfaces to cure fully then wash and sand Hardwoods Sand with 80 grit paper Teak oily woods Wipe with acetone 15 minutes before coating allowing the solvent to evaporate before coating Use G flex epoxy for bonding Porous woods No special preparation needed If surface is burnished possibly by dull planer or saw blades sand with 80 grit paper to open pores Remove dust Steel lead Remove contamination sand or grind to bright metal coat with epoxy then wet sand freshly applied epoxy into surface Re coat or bond after first coat gels Aluminum Remove contamination sand to a bright finish and prepare with 860 Alumi
20. e the epoxy into the cloth which may trap air in the fabric and show through the clear finish Apply enough epoxy to saturate the fabric and the wood below After several minutes lay on ad ditional epoxy to dry white areas If epoxy appears milky due to high humidity or over working warm the surface by passing a heat gun or hair dryer over the surface Use low heat to avoid out gassing Be sure to use 207 Hardener for clear finishes cloth in position If you are applying the cloth vertically or overhead you may want to thicken the epoxy slightly with filler then wait until it becomes sticky Work out wrin kles by lifting the edge of the cloth and smoothing from the center with your gloved hand or a plastic spreader Apply asecond coat of epoxy witha foam roller Apply enough epoxy to thoroughly wet out the cloth Remove the excess epoxy with a plastic spreader using long overlapping strokes The cloth should appear consistently transparent with a smooth cloth texture Follow steps 7 and 8 under the Dry method above to finish the procedure Any remaining irregularities or transitions between cloth and substrate can be faired by us ing an epoxy filler fairing compound if the surface is to be painted Any additional fairing done after the final coating should receive several additional coats over the faired area E WEST SYSTEM User Manual amp Product Guide 11 User Manual Epoxy barrier coating Figure 30 Roll light
21. er any areas that need protection from spills Figure 9 Apply resin hardener mixture Pre Aaa n Two step bonding 1 Wet out bonding surfaces Apply an unthickened resin hardener mixture to the sur faces to be joined Figure 9 Wet out small or tight areas with a disposable brush Wet out larger areas with a foam roller or by spreading the resin hardener mixture evenly over the surface with a plastic spreader You may proceed with step two immediately or any time before the wet out coat becomes tack free 2 Apply thickened epoxy to one bonding surface Modify the resin hardener mixture by stirring in the appropriate filler until it becomes thick enough to bridge any gaps be tween the mating surfaces and to prevent resin starved joints Apply enough of the mixture to one of the surfaces so that a small amount will squeeze out when the surfaces are joined together with a force equivalent to a firm hand grip Figure 10 RT Figure 10 Apply thickened epoxy to one of the bonding surfaces Thickened epoxy can be applied immediately over the wet out surface or any time be fore the wet out is no longer tacky For most small bonding operations add the filler to the resin hardener mixture remaining in the batch that was used for the wet out Mix enough resin hardener for both steps Add the filler quickly after the surface is wet out and allow for a shorter working life of the mixture 3 Clamp components Attach clamps as necessary
22. er the fi nal coat has cured overnight wash and sand it to prepare for the final finish See Special preparation Cured epoxy on page 6 amp Final surface preparation Figure 32 Sand to a smooth finish 12 Proper finishing techniques will not only add beauty to your efforts but will also protect your work from ultraviolet light which will break down epoxy over time The most com mon methods of finishing are painting or varnishing These coating systems protect the ep oxy from ultraviolet light and require proper preparation of the surface before application Preparation for the final finish is just as important as it is for re coating with epoxy The sur face must first be clean dry and sanded 1 Allow the final epoxy coat to cure thoroughly 2 Wash the surface with a Scotch brite pad and water to remove amine blush Dry with paper towels 3 Sand to a smooth finish Figure 32 If there are runs or sags begin sanding with 80 grit paper to remove the highest areas Sand until the surface feels and looks fair Complete sanding with the appropriate grit for the type of coating to be applied check coating WEST SYSTEM User Manual amp Product Guide Figure 33 Rinse the surface with fresh water after sanding User Manual instructions Paint adhesion relies on the mechanical grip of the paint keying into the sanding scratches in the epoxy s surface If a high build or filling primer is to be applied 80
23. es should be 1 Clean Bonding surfaces must be free of any contaminants such as grease oil wax or mold release Clean contaminated surfaces with lacquer thinner acetone or other appro priate solvent Figure 6 Wipe the surface with paper towels before the solvent dries Clean surfaces before sanding to avoid sanding the contaminant into the surface Follow all safety precautions when working with solvents 2 Dry All bonding surfaces must be as dry as possible for good adhesion If necessary ac celerate drying by warming the bonding surface with a hot air gun hair dryer or heat lamp Figure 7 Use fans to move the air in confined or enclosed spaces Watch for condensation when working outdoors or whenever the temperature of the work environment changes 3 Sanded Sand smooth non porous surfaces thoroughly abrade the surface Figure 8 80 grit aluminum oxide paper will provide a good texture for the epoxy to key into Be sure the surface to be bonded is solid Remove any flaking chalking blistering or old coat ing before sanding Remove all dust after sanding Special preparation for various materials Cured epoxy Amine blush may appear as a wax like film on cured epoxy surfaces except for epoxy 207 Special Clear Hardener It is a byproduct of the curing process and may be more noticeable in cool moist conditions Amine blush can clog sandpaper and inhibit sub sequent bonding but it is water soluble and can easily b
24. g stick or a putty knife Figure 14 Fiberglass cloth or tape may be applied over the fillet area before the fillet has cured or after the fillet is cured and sanded 4 Sand smooth with 80 grit sandpaper after the fillet has fully cured Wipe the surface clean of any dust and apply several coats of resin hardener over the entire fillet area be fore final finishing m Figure 15 Wet out a standard pilot hole and install the fastener Epoxy Annulus Figure 16 Drill oversized holes to in crease the exposed substrate area and the amount of epoxy around the fastener Installing screws and other threaded fasteners with WEST SYSTEM epoxy dramatically im proves load carrying capacity by spreading the fastener s load into a greater area of the sub strate There are several methods or levels of hardware bonding depending on the loads on the hardware Basic fastener bonding For improved pullout strength and waterproof connections the easiest fastener bonding method is to simply wet out stripped fastener holes and new pilot holes before installing the screws Epoxy penetrates the fiber around the hole effectively increasing the fastener di ameter Epoxy also provides a stronger interface with the fastener threads than wood fiber and keeps out water 1 Wet out a standard size pilot hole Work the mixture well into the hole with a pipe cleaner or syringe Figure 15 Thicken a second coat of epoxy as necessary for stripped
25. h coating Together the two form a protective system far more durable than either coating by itself Protection from sunlight is a primary consideration in the selection of a finish coating Long term UV protec tion of the barrier coat depends on how well the finish coating itself re sists UV and keeps its pigments or its shield of UV filters on the surface of the epoxy barrier coat A high gloss finish reflects a higher proportion of the light hitting the surface than a dull surface All other thing being equal a white especially a glossy white coating will last the longest Coating compatibility Most types of coatings are compati ble with epoxy Thoroughly cured epoxy is an almost completely inert hard plastic Most paint solvents will not soften swell or react with it One part polyurethanes and polyes ter gelcoat can be affected by epoxy amines and if used must be applied when the epoxy is thoroughly cured generally after two weeks at room temperature A thorough cure can be achieved much quicker with elevated temperature post curing Post curing will also improve epoxy s thermal properties and is recommended if dark paint is to be applied over epoxy Finish coating types Latex paints are compatible with epoxy even partially cured epoxy and they do an ade quate job of protecting the epoxy barrier from UV radiation In many architectural applica tions a latex paint may be the most suitable coating to use Thei
26. hape around the base Figure 19 c Al low the epoxy to cure fully before loading Protect exposed epoxy from UV Bonding studs Bond threaded rods or studs into the substrate instead of bolts or screws and attach the hardware with nuts This variation is appropriate for many engine motor or machine in stallations Coat the base with wax mold release to make the hardware removable Al though the hardware is not bonded to the substrate the epoxy will still provide a bearing surface that perfectly matches and supports the base of the hardware 1 Prepare the stud threaded rod by waxing the upper end above the surface and cleaning the lower end below the surface Place a nut on the stud positioned with the top of the nut slightly above the surface 2 Fill the hole 2 3 full with epoxy Allow to penetrate and refill as necessary 3 Wet out the lower end of the stud and push it into the epoxy filled hole Top off the hole or clean away excess as necessary Allow the epoxy to cure thoroughly before attaching hardware and tightening the nut Figure 20 Removing fasteners If you know that you will want to remove the fastener you can coat the threads with wax or mold release contaminating the surface enough to prevent a good bond Remove a permanently bonded fastener by applying heat to the head of the fastener with a soldering iron or propane torch Use a heat shield to protect the surrounding area Heat will travel down the fa
27. inal epoxy coat to cure thoroughly Allow several days if neces sary for slow hardeners at cooler temperatures Apply moderate heat to complete the cure if necessary See Controlling cure time page 3 1 Use a different type of paint Some paints and varnishes may be incom patible with some hardeners If unsure test for compatibility on a coated piece of scrap material 2 Use 207 Hardener It is compatible with most paints and varnishes Remove the amine blush and sand the surface thoroughly before applying paints or varnishes See Final surface preparation page 12 1 Mix smaller batches 2 Transfer the mixture to a container with more surface area immediately after mixing See Controlling cure time page 3 Dispensing and Mixing page 4 Use 206 Slow or 209 Extra Slow Hardener in very warm weather Apply thick areas of fill in several thin layers 1 Coat the wood as its temperature is dropping after warming the wood with heaters or during the later part of the day 2 Apply a thinner coat allowing air to escape easier 3 Tip off the coating with a roller cover brush to break bubbles See Caution top of page 4 After applying epoxy with an 800 Roller Cover force epoxy into pinholes with a stiff plastic or metal spreader held at a low or nearly flat angle Re coat and tip off coating after all pinholes are filled 1 Be sure mixing equipment is clean Avoid waxed mixing containers 2 Be sure surface is pr
28. ing clamps C clamps and bar clamps rubber bands packaging tape applying weights and vacuum bagging If necessary cover clamp pads with tape or use polyethylene sheeting or release fabric under the clamps so they don t inadvertently bond to the surface Sta ples nails or drywall screws are often used where conventional clamps will not work In a corrosive environment any fasteners left in should be a non corroding alloy such as bronze In some cases the thickened epoxy or gravity will hold parts in position without clamps Avoid excessive clamping pressure User Manual 4 Fill the hole with thickened epoxy adhesive filler Use 404 High Density preferred or 406 Colloidal Silica 5 Install the fasteners with just enough force to hold the hardware in place Allow the ep oxy to cure thoroughly before applying load to the hardware Figure 16 b Bonding hardware Bonding hardware goes a step beyond bonding the fasteners only By bonding the hardware base directly to the surface you further increase hardware load capacity and provide a solid bearing surface for the hardware It also seals the wood underneath and is a stronger lon ger lasting attachment than bonding the fasteners only It is especially useful to mount hard ware on curved uneven or unlevel surfaces 1 Prepare the mounting surface and the hardware base for good adhesion Surface prepa ration page 6 2 Wet out the oversized hole with epoxy Allow
29. ive in the final five coats provides maximum moisture protection recommended for polyester fiberglass boats with gelcoat blisters Additives or pigments should not be added to the first coat Mixing thinners with WEST SYSTEM epoxy is not recommended see Thinning epoxy page 25 Disposable thin urethane foam rollers such as WEST SYSTEM 800 Roller Covers allow you greater control over film thickness are less likely to cause the epoxy to exotherm and leave less stipple than thicker roller covers Cut the covers into narrower widths to reach difficult areas or for long narrow surfaces like stringers A paint brush can be used for smaller areas if the bristles are stiff enough to spread the epoxy to an even film If necessary cut the bris tles shorter Foam brushes are generally too flexible Complete all fairing and cloth application before beginning the final coating Allow the temperature of porous surfaces to stabilize before coating Otherwise as the material warms up air within the porous material may expand and pass from the material out gas sing through the coating and leave bubbles in the cured coating 1 Prepare the surface for bonding Surface preparation page 6 2 Mix only as much resin hardener as you can apply during the open time of the mixture Pour the mixture into a roller pan as soon as it is mixed thoroughly 3 Load the roller with a moderate amount of the epoxy mixture Roll the excess out on the ramp part of
30. l 10 Fiberglass cloth is applied to surfaces to provide reinforcement and or abrasion resistance or in the case of Douglas Fir plywood to prevent grain checking It is usually applied after fairing and shaping are completed and before the final coating operation It is also applied in multiple layers and in combination with other materials to build composite parts Fiberglass cloth may be applied to surfaces by either of two methods The dry method re fers to applying the cloth over a dry surface The wet method refers to applying the cloth to an epoxy coated surface often after the wet out coat becomes tacky which helps it cling to vertical or overhead surfaces Since this method makes it more difficult to position the cloth the dry method is the preferred method especially with thinner cloth Dry method 1 Prepare the surface as you would for bonding Surface preparation page 6 2 Position the cloth over the surface and cut it several inches larger on all sides If the sur face area you are covering is larger than the cloth size allow multiple pieces to overlap by approximately two inches On sloped or vertical surfaces hold the cloth in place with masking or duct tape or with staples 3 Mix a small quantity of epoxy three or four pumps each of resin and hardener 4 Pour a small pool of resin hardener near the center of the cloth 5 Spread the epoxy over the cloth surface with a plastic spreader working
31. ly and randomly over a small area Spread the epoxy into a thin even film Figure 31 Tip off the coating by drag ging a foam roller brush lightly over the fresh epoxy Barrier coat thickness Epoxy applied with the 800 Roller Cover at room temperature 70 F and tipped off as described right results in a film 3 4 mils thick A 6 or 7 mil film thickness two coats three coats if sanded provides an excellent moisture barrier for most exterior surfaces A 9 or 10 mil film thickness is the minimum recommended for hull bottoms or other surfaces that are continuously wet Additional coats provide additional moisture protection up to 20 mils five or six coats Six coats with the last five modified with 422 Barrier Coat Additive provide maximum protection and are generally recommended only for polyester fiberglass hull bottoms prone to gelcoat blistering Epoxy film thickness per coat will vary with temperature thinner in warm tempera tures thicker in cooler temperatures The object of barrier coating is to build up an epoxy coating that provides an effective mois ture barrier and a smooth base for final finishing Apply a minimum of two coats of WEST SYSTEM epoxy for an effective moisture barrier three coats if sanding is to be done recommended for most wooden boats Moisture pro tection will increase with additional coats up to six coats or about a 20 mil thickness Six coats with 422 Barrier Coat Addit
32. moving epoxy note page 5 2 Check correct number of pump strokes use equal strokes of resin and hardener DO NOT add extra hardener for faster cure 3 Check for correct pump 5 1 or 3 1 ratio 4 Check pump metering ratio see pump instructions See Dispensing page 4 1 Allow extra curing time in cool weather 2 Apply heat to maintain the chemical reaction and speed the cure Raise the temperature above the hardener s minimum recommended cure tem perature NOTE Unvented kerosene or propane heaters can inhibit the cure of epoxy and contaminate epoxy surfaces 3 Use a faster hardener designed to cure at lower temperatures See Controlling cure time page 3 1 Remove epoxy Do not apply additional material over non curing epoxy See Removing epoxy note page 5 2 Mix resin and hardener together thoroughly to avoid resin rich and hard ener rich areas 3 Add fillers or additives after resin and hardener have been thoroughly mixed See Mixing page 4 1 Remove epoxy Do not apply additional material over non curing epoxy See Removing epoxy note page 5 2 Check for proper resin and hardener Resin will not cure properly with other brands of hardener or with polyester catalysts See above Wet out bonding surfaces before applying thickened epoxy Re wet very porous surfaces and end grain See Two step bonding page 7 Clean and sand the surface following the procedure on page 6 Sand wood surfaces after pl
33. o dry before re coating After re coating wood surfaces with epoxy it s a good idea to brush the wet epoxy in the direction of the grain with a wire brush to improve adhesion Removing fiberglass cloth applied with epoxy Use a heat gun to heat and soften the epoxy Start in a small area a near a corner or edge Apply heat until you can slip a putty knife or chisel under the cloth about 250 F Grab the edge with a pair of pliers and slowly pull up on the cloth while heating just ahead of the separation On large areas use a utility knife to score the glass and remove in narrower strips Result ing surface texture may be coated or remaining epoxy may be removed as follows Removing cured epoxy coating Use a heat gun to soften the epoxy about 250 F Heat a small area and use a paint or cabinet scraper to remove the bulk of the coating Sand the surface to remove the remain ing material Provide ventilation when heating epoxy WEST SYSTEM User Manual amp Product Guide User Manual BASIC TECHNIQUES The following basic techniques are common to most repair or building projects regardless of the type of structure or material you are working with Surface preparation i Figure 6 Clean the surface Use a sol vent if necessary to remove all con taminates Figure 7 Dry the surface Allow wet surfaces to dry thoroughly or use heat or a fan to speed drying Figure 8 Sand non porous surfaces Provide a
34. operly prepared Use proper grit sandpaper for the type of coating you are applying See paint or varnish manufacturer s in structions for proper surface preparation After surface is prepared avoid contamination fingerprints exhaust fumes rags with fabric softener sili cone Coat within hours of preparation After wet sanding rinse water should sheet without beading beading indicates contamination Wipe with appropriate solvent and re rinse until rinse water no longer beads Contact the Gougeon technical staff if you have additional questions Red color is a normal condition It will not affect epoxy handling or cured strength Avoid using hardener for clear coating or exposed areas where color is not desired WEST SYSTEM User Manual amp Product Guide 15
35. or by writing or calling our technical staff We are always interested in your views and welcome suggestions about our products and service We encourage you to call or write with com ments on WEST SYSTEM products and their use West System Inc P O Box 665 Bay City MI 48707 USA 866 937 8797 toll free fax 989 684 1374 www westsystem com Because West System Inc cannot control how its products will be used it makes no war ranties either expressed or implied including no warranties of merchantability and fitness for purpose intended West System Inc will not be liable for incidental or consequential damages WEST SYSTEM products are manufactured for West System Inc by Se Gougeon Brothers Inc Bay City MI USA WEST SYSTEM User Manual amp Product Guide 1 User Manual HANDLING EPOXY This section explains the fundamentals of epoxy safety curing and the steps for proper dispensing mixing and adding fillers to assure that every batch cures to a reliable high strength solid Epoxy safety a Precautions Epoxies are safe when handled properly To use WEST SYSTEM Ep oxies safely you must understand their hazards and take precautions to avoid them Hazards The primary hazard associated with epoxy involves skin contact WEST SYSTEM Resins may cause moderate skin irritation WEST SYSTEM Hard eners are corrosive and may cause severe skin irritation Resins and hardeners are also sensitizers and may cau
36. or oversized holes 2 Insert the fastener in the hole and allow the epoxy to cure Advanced fastener bonding For greater strength and stability drill oversized holes to increase the exposed substrate area and the amount of epoxy around the fastener 1 Drill oversized holes 2 3 3 4 the depth of the fastener The hole diameter is 1 4 larger than the fastener diameter Figure 16 a 2 Drill a normal sized pilot hole at the bottom of the oversized hole to the full length of the fastener The normal sized pilot hole serves to hold or clamp the hardware in position until the epoxy cures If the fastener hardware can be clamped by other means the over sized hole can be extended to the end of the fastener 3 Wet out the holes and the fastener with epoxy Allow the epoxy to thoroughly soak into the exposed end grain of the wood WEST SYSTEM User Manual amp Product Guide Figure 17 Coat the hardware bottom and the fastener threads with thick ened epoxy Backing Plate Figure 18 Tighten fasteners until a small amount of epoxy squeezes from the joint Figure 19 Support the base in position with blocking Fill the void with thick ened epoxy _ Slightly above surface Figure 20 Bond threaded rods or studs into the substrate as an alterna tive for easily removable hardware Clamping Any method of clamping is suitable as long as there is no movement between the parts being joined Common methods include spr
37. pears as a shiny area while a properly wet out surface appears evenly transparent with a smooth cloth texture Later coats of epoxy will fill the weave of the cloth 7 Trim the excess Figure 26 and overlapped cloth after the epoxy has reached its initial cure The cloth will cut easily with a sharp utility knife Trim overlapped cloth if de sired as follows Figure 26 Trim excess cloth after the 6 epoxy gels a Place a metal straightedge on top of and midway between the two overlapped edges b Cut through both layers of cloth with a sharp utility knife Figure 27 being very care ful not to cut too deeply c Remove the topmost trimming and then lift the opposite cut edge to remove the overlapped trimming Figure 28 d Re wet the underside of the raised edge with epoxy and smooth into place The result should be a near perfect butt joint eliminating double cloth thickness A lapped joint is stronger than a butt joint so if appearance is not important you may want to leave the overlap and fair in the unevenness after coating 8 Coat the surface to fill the weave before the wet out becomes tack free Figure 29 Fol low the procedures for final coating in the next section It will take two or three coats to completely fill the weave of the cloth and provide a thick enough coating to allow for a final sanding that will not affect the cloth Figure 27 Trim overlapped cloth after the epoxy gels Figure 28 Remove
38. poxy mixture to the desired consistency The thickness of a mixture re quired for a particular job is controlled by the amount of filler added There is no strict for mula or measuring involved use your eye to judge what consistency will work best Figure 4 gives you a general guide to the differences between neat unthickened epoxy and the three consistencies referred to in this manual Unthickened mixture Slightly thickened Moderately thickened Maximum thickness Figure 4 Epoxy can be CONSISTENCY thickened to the ideal con SYRUP CATSUP MAYONNAISE PEANUT BUTTER sistency needed for a par ticular job The proce dures in this manual refer to four common consis GENERAL tencies syrup catsup APPEARANCE mayonnaise and peanut butter CHARACTERISTICS D PS off vertical Sage dow vertical alle ao surfaces surfaces peaks fall over peaks stand up Coating wetting out Laminating bonding flat Genera bondi Gap filling filletin USES before bonding applying panels with large filleting e anna io er surface areas injecting with a syringe fiberglass graphite and other fabrics surfaces bonding Always add fillers in a two step process 1 Mix the desired quantity of resin and hardener thoroughly before adding fillers Begin with a small batch allow room for the filler 2 Blend in small handfuls or scoops of the appropriate filler until the desired consistency is reached Figure 5 For maximum strength add only
39. r af ter the epoxy is applied At room temperature supplemental heat is useful when a quicker cure is desired NOTE Unvented kerosene or propane heaters can inhibit the cure of epoxy and contaminate epoxy surfaces with unburned hydrocarbons WEST SYSTEM User Manual amp Product Guide 3 User Manual Post curing You can improve epoxy s thermal performance and reduce the potential for fabric print through by applying modest heat to the epoxy after it has cured to a solid state Contact our technical staff for more in formation about post curing epoxy Dispensing and Mixing CAUTION Heating epoxy that has not gelled will lower its viscosity allowing the epoxy to run or sag more easily on vertical surfaces In addition heating epoxy applied to a porous substrate soft wood or low density core material may cause the substrate to out gas and form bubbles or pinholes in the epoxy coating To avoid out gassing wait until the epoxy coating has gelled before warming it Never heat mixed epoxy in a liquid state over 120 F 49 C Regardless of what steps are taken to control the cure time thorough planning of the application and assembly will allow you to make maximum use of epoxy s open time and cure time E 105 Resin and Harder Figure 2 Dispense the proper propor tions of resin and hardener With Mini Pumps Pump one full pump stroke of resin for each one full pump stroke of hardener 1 stroke 1
40. r coat If you are unsure of compatibility or have curing or adhesion problems with a specific bottom paint use only a primer recommended for that bottom paint over the barrier coat Follow the recommendations given for preparation of fiberglass surfaces Other paints including marine LP s and primers are not recommended for use below the waterline Primers are usually not needed to help a paint film bond to epoxy although interfacing primers may be required with some specialized bottom paints and high build primers are useful for hiding scratches or flaws in the substrate If the instructions on your paint or var nish recommend a specially primed surface follow the recommendations given for fiber glass preparation Self etching primers do not work well on an epoxy coating because of epoxy s chemical resistance Polyester gelcoat is a pigmented version of the resin used to build fiberglass boats and other products Gelcoat is sprayed into a mold before the glass fabric and resin are applied to pro vide a smooth pre finished surface when the part is removed from the mold It is not often used as a post production finish coating but it can be applied over epoxy and is useful in some repair situations Epoxy must be cured thoroughly Refer to 002 550 Fiberglass Boat Repair amp Maintenance for detailed information on patching gelcoat over an epoxy repair Follow all instructions from the coating systems manufacturer It is a good idea to mak
41. r durability is limited Alkyd finishes enamel alkyd enamel marine enamel acrylic enamel alkyd modified ep oxy traditional varnish and spar varnish offer ease of application low cost low toxicity and easy availability Their disadvantages are low UV resistance and low abrasion resistance One part polyurethanes offer easy application cleanup and better properties than alkyds They are also more expensive and some may be incompatible with amine cure epoxy sys tems such as WEST SYSTEM epoxy although 207 Hardener may offer better compatibility Be sure epoxy has cured thoroughly Make a test panel to assure compatibility Epoxy paints are available in one part and two part versions Two part epoxies offer many characteristics similar to the higher performance polyurethanes They are durable and chemical resistant but offer limited UV protection compared to the linear polyurethanes Two part linear polyurethane LP paints offer the most durable protection available LPs are available as pigmented or clear coatings and offer excellent UV protection gloss reten tion abrasion resistance plus compatibility with epoxy However compared to other types of coatings they are expensive require more skill to apply and present a greater health hazard especially when sprayed Bottom paints are available in a variety of formulations Most bottom paint systems are compatible with epoxy and can be applied directly over a prepared epoxy barrie
42. se an allergic reaction simi lar to poison ivy Susceptibility and the severity of a reaction varies with the individual Although most peo ple are not sensitive to WEST SYSTEM Resins and Hardeners the risk of becoming sensitized increases with repeated contact For those who become sensitized the severity of the reaction may increase with each contact These hazards also ap ply to the sanding dust from epoxy that has not fully cured These haz ards decrease as resin hardener mix tures reach full cure Refer to product labels or Material Safety Data Sheets MSDS for specific product warnings and safety infor mation 1 4 Avoid contact with resin hardeners mixed epoxy and sanding dust from epoxy that is not fully cured Wear protective gloves and clothing whenever you handle WEsT SYSTEM epoxies Barrier skin creams provide additional protection If you do get resin hardener or mixed epoxy on your skin remove it as soon as possible Resin is not water solu ble use a waterless skin cleanser to remove resin or mixed epoxy from your skin Hard ener is water soluble wash with soap and warm water to remove hardener or sanding dust from your skin Always wash thoroughly with soap and warm water after using ep oxy Never use solvents to remove epoxy from your skin Stop using the product if you develop a reaction Resume work only after the symptoms disappear usually after several days When you resume work improve your safet
43. stener softening the epoxy in contact with it At about 250 F the epoxy should soften enough to allow the fastener to be backed out Allow more time for heat to travel down longer or larger diameter fasteners W WEST SYSTEM User Manual amp Product Guide 9 User Manual Figure 21 Wet out porous surfaces be fore applying fairing compound int we Figure 22 Apply fairing compound to fill all voids and smooth to shape wean a a gt y y NZ a Figure 23 Sand cured fairing com pound to desired contour Fairing refers to the filling of low areas and the shaping and smoothing of a surface to blend with the surrounding areas and appear fair to the eye and touch After major structural assembly has been completed final fairing can be easily accomplished with WEST SYSTEM epoxy and low density fillers 1 Prepare the surface as you would for bonding Surface preparation page 6 Sand smooth any bumps or ridges on the surface and remove all dust from the area to be faired 2 Wet out porous surfaces with unthickened epoxy Figure 21 3 Mix resin hardener and 407 Low Density or 410 Microlight filler to a peanut butter consistency The thicker the mixture the easier it will be to sand when cured 4 Trowel on the thickened epoxy mixture with a plastic spreader working it into all voids and depressions Smooth the mixture to the desired shape leaving the mixture slightly higher than the surrounding area
44. stroke Resin Hardener Figure 3 Stir resin and hardener to gether thoroughly at least 1 minute longer in cooler temperatures More information If you have any questions about selecting or using WEST SYSTEM products that are not an swered in this manual contact our technical staff Call 866 937 8797 toll free or visit www westsystem com where you can fill out a form and receive an emailed response to your question Careful measuring of epoxy resin and hardener and thorough mixing are essential for a proper cure Whether the resin hardener mixture is applied as a coating or modified with fillers or additives observing the following procedures will assure a controlled and thor ough chemical transition to a high strength epoxy solid Dispensing Dispense the correct proportions of resin and hardener into a clean plastic metal or wax free paper container Figure 2 Don t use glass or foam containers because of the po tential danger from exothermic heat buildup DO NOT attempt to adjust the epoxy cure time by altering the mix ratio An accurate ratio is essential for a proper cure and full development of physical properties Dispensing with Mini Pumps Most problems related to curing of the epoxy can be traced to the wrong ratio of resin and hardener To simplify dispensing and reduce the possibility of errors we recommend using calibrated WEST SYSTEM Mini Pumps to meter the correct working ratio of resin to hard
45. t cures epoxy The amount of heat produced depends on the thickness or exposed surface area of mixed epoxy In a thicker mass more heat is retained causing a faster reaction and more heat The mixing container s shape and the mixed quantity have a great affect on this exothermic reaction A contained mass of curing epoxy 8 fl oz or more in a plastic mixing cup can quickly gener ate enough heat to melt the cup and burn your skin However if the same quantity is spread into a thin layer exothermic heat is dissipated and the epoxy s cure time is determined by the ambient temperature The thinner the layer of curing epoxy the less it is affected by exothermic heat and the slower it cures Adapting to warm and cool temperatures In warm conditions gain open time by using a slower hardener if possible Mix smaller batches that can be used up quickly or pour the epoxy mixture into a container with greater surface area a roller pan for example thereby allowing exothermic heat to dissipate and extending open time The sooner the mixture is transferred or applied after thorough mix ing the more of the mixture s useful open time will be available for coating lay up or assembly In cool conditions use a faster hardener or use supplemental heat to raise the epoxy tem perature above the hardener s minimum recommended application temperature Use a hot air gun heat lamp or other heat source to warm the resin and hardener before mixing o
46. tandards This test uses a special fixture in one of the lab s MTS test machines to simulate the pressure loads a section of a hull would endure in a lifetime on the water In 1999 the American Society for Testing and Materials approved the Hydromat test as an official ASTM standard D6416 This unique testing program is used by designers and builders around the world to evaluate various combinations of sandwich compos ite materials and epoxy formulations and ultimately build lighter stronger safer structures The information provided by a comprehensive test program along with our own building experience and feedback from our customers contrib utes to a data base on epoxies and epoxy composites that has been grow ing for over thirty five years This knowledge is invaluable not only for achieving the proper balance of properties required for a versatile high quality marine epoxy it assures that the building and repair infor mation provided by Gougeon Brothers is up to date and reliable Technical support To help you make the most of WEST SYSTEM Epoxy s balanced perfor mance and versatility Gougeon Brothers provides you with one other important ingredient knowledge Whether your project is large or small WesT SYSTEM technical publications and videos offered in this guide provide detailed procedures and instructions for specific repair and construction applications Further assistance can be obtained by vis iting our website
47. the epoxy gently from the pool into the dry areas Figure 24 Use a foam roller or brush to wet out fabric on vertical surfaces Properly wet out fabric is transparent White areas indicate dry fabric If you are applying the cloth over a porous surface be sure to leave enough epoxy to be absorbed by both the cloth and the surface below it Try to limit the amount of squeegeeing you do The more you work the wet surface the more minute air WEST SYSTEM User Manual amp Product Guide User Manual bubbles are placed in suspension in the epoxy This is especially important if you plan to use a clear finish see Clear wood finishes below left You may use a roller or brush to apply epoxy to horizontal as well as vertical surfaces Smooth wrinkles and position the cloth as you work your way to the edges Check for dry areas especially over porous surfaces and re wet them with epoxy as necessary be fore proceeding to the next step If you have to cut a pleat or notch in the cloth to lay it flat on a compound curve or corner make the cut with a pair of sharp scissors and over lap the edges for now Squeegee away excess epoxy before the first batch begins to gel Figure 25 Slowly drag the spreader over the fabric at a low almost flat angle using even pressured overlap ping strokes Use enough pressure to remove excess epoxy that would allow the cloth to float off the surface but not enough pressure to create dry spots Excess epoxy ap
48. the epoxy to soak into the exposed end grain of the wood as with faster bonding 3 Coat the bottom contact surface of the hardware with unthickened epoxy Wire brush or sand the wet epoxy into the surface with 50 grit sandpaper 4 Inject a non sagging epoxy 404 or 406 mixture into the hole Use enough mixture so there are no voids in the hole after inserting the fastener Coat the bottom of the hard ware and the fastener threads with thickened epoxy Figure 17 5 Place the hardware in position Insert and tighten fasteners until a small amount of the mixture squeezes out of the joint Figure 18 6 Remove excess epoxy or shape into a fillet Allow the epoxy to cure at least 24 hours be fore applying load to the hardware Allow more time in cool weather Casting a base Use the thickened epoxy to cast a base under the hardware when mounting hardware to a curved or uneven surface or mounting hardware at an angle to the surface 1 Prepare the fasteners holes substrate and base as described above 2 Bond small blocks to the substrate to support the base at the desired height and position e g winch base Figure 19 a 3 Apply enough thickened epoxy to cover the blocks If the gap between the base and the surface is over 1 2 fill the gap in two separate layers to avoid exotherm 4 Place the hardware in position resting on the blocks Figure 19 b and install the fasteners 5 Smooth the excess epoxy into the desired fillet s
49. the mixing stick to reach the inside corner of the pot If you are us ing a power mixer occasionally scrape the sides and corners of the mixing pot while mix ing If you are going to be using the mixture for coating quickly pour it into a roller pan to extend the open time A WARNING Curing epoxy generates heat Do not fill voids or cast layers of epoxy thicker than 2 thinner if enclosed by foam or other insulating material Several inches of mixed epoxy in a confined mass such as a mixing cup will generate enough heat to melt a plastic cup burn your skin or ignite combustible materials if left to stand for its full pot life For this reason do not use foam or glass mixing containers or pour into confined spaces If a pot of mixed epoxy begins to exotherm heat up quickly move it outdoors Avoid breathing the fumes Do not dispose of the mixture until the reaction is complete and has cooled E WEST SYSTEM User Manual amp Product Guide User Manual Adding fillers and additives Fillers Throughout this and other WEST SYSTEM manuals we refer to epoxy or resin hardener mixture meaning mixed resin and hardener without fillers added and thickened mixture or thickened epoxy meaning mixed resin and hardener with fillers added Fillers are used to thicken epoxy for specific applications such as bonding or fairing After selecting an appropriate filler for your job see Filler Selection Guide page 23 use it to thicken the e
50. the mixture approaches the final cure phase Solid Final cure phase The epoxy mixture has cured to a solid state and can be dry sanded You will no longer be able to dent it with your thumbnail At this point the epoxy has reached most of its ul timate strength so clamps can be re moved A new application of epoxy will no longer chemically link to it so the surface of the epoxy must be properly prepared and sanded before re coating to achieve a good me chanical secondary bond See Sur face preparation page 6 The mixture will continue to cure for the next several days to two weeks at room temperature becom ing an inert plastic solid Figure 1 As it cures mixed epoxy passes from a liquid state me through a gel state to a solid Liquid ital cure Solid state Open time phase Finalcure gt S ain Cure time is shorter when the Tack free epoxy is warmer SURE amp PREPARE SURFACE Cure time is onger when the epoxy is cooler Epoxy Temperature Cure time after mixing Controlling cure time Open time and overall cure time govern much of the activity of building and repairing with epoxy Open time dictates the time available for mixing application smoothing shaping as sembly and clamping Cure time dictates how long you must wait before removing clamps or before you can sand or go on to the next step in the project Two factors determine an epoxy mixture s open time and overall cure time
51. the roller pan to get a uniform coating on the roller 4 Roll lightly and randomly over an area approximately 2 X2 to transfer the epoxy evenly over the area Figure 30 5 As the roller dries out increase pressure enough to spread the epoxy into a thin even film Increase the coverage area if necessary to spread the film more thinly and evenly The thinner the film the easier it is to keep it even and avoid runs or sags in each coat 6 Finish the area with long light even strokes to reduce roller marks Overlap the previ ously coated area to blend both areas together 7 Coat as many of these small working areas as you can with each batch If a batch begins to thicken before it can be applied discard it and mix a fresh smaller batch 8 Tip off the coating by dragging a foam roller brush lightly over the fresh epoxy in long even overlapping strokes after each batch is applied Use enough pressure to smooth the stipple but not enough to remove any of the coating Figure 31 Alternate the direction in which each coat is tipped off 1st coat vertical 2nd coat horizontal 3rd coat vertical etc An 800 Roller Cover can be cut into segments to make a tipping brushes Re coating Apply second and subsequent coats of epoxy following the same procedures Re coat when the previous coat is still tacky about as tacky as masking tape To avoid sanding between coats apply all of the coats when previous coats have cured to this tacky stage Aft
52. to hold the components in place Use just enough clamping pressure to squeeze a small amount of the epoxy mixture from the joint indicating that the epoxy is making good contact with both mating surfaces Fig ure 11 Avoid using too much clamping pressure which can squeeze all of the epoxy mixture out of the joint 4 Remove or shape excess adhesive that squeezes out of the joint as soon as the joint is se cured with clamps An 804 mixing stick is an ideal tool for removing the excess Figure 12 Allow to cure thoroughly before removing clamps Figure 11 Clamp components in place before the epoxy gels Single step bonding Single step bonding is applying the thickened epoxy directly to both bonding surfaces with out first wetting out the surfaces with neat resin hardener We recommend that you thicken the epoxy no more than is necessary to bridge gaps in the joint the thinner the mixture the more it can penetrate the surface and that you do not use this method for highly loaded joints especially when bonding end grain or other porous surfaces N Figure 12 Remove or shape excess epoxy that squeezes out of the joint Structural bonding Joint strength the ability to adequately transfer a load from one part to another de pends on the combined effects of three factors GLUE STRENGTH Aa Adhesion Careful metering and Joint thorough mixing will assure the epoxy mixture cures to full strength ADHESION For the
53. ually formulating testing and improving WEST SYSTEM resins and hardeners and developing specialty epoxies to produce the most reliable and well balanced epoxy systems available Potential resin and hardener formulas ingredients and combinations are tested to compare fatigue strength compression strength glass transition temperature and peak exotherm Qualified samples undergo additional tests for hardness tensile strength tensile elongation tensile modulus flexural strength flexural modulus heat deflection temperature impact resistance and moisture exclusion effectiveness This level of testing in sures that any change in a formula will improve one or more of a prod uct s characteristics without diminishing any characteristics WEST SYSTEM User Manual amp Product Guide Comprehensive testing Good science and comprehensive testing are essential not only for the de velopment of improved epoxy formulations but also for the develop ment of better construction and repair methods In addition to the tests conducted to support in house product development our materials test lab also conducts testing to support outside builders designers and gov ernment organizations in the engineering of epoxy composite structures Aside from performing a battery of standard ASTM tests we have devel oped new testing methods to evaluate adhesives and composites Some of these tests like our patented Hydromat Panel test have become industry s
54. y pre cautions to prevent exposure to epoxy its vapors and sanding dust If problems persist discontinue use and consult a physician Protect your eyes from contact with resin hardeners mixed epoxy and sanding dust by wearing appropriate eye protection If contact occurs immediately flush the eyes with water under low pressure for 15 minutes If discomfort persists seek medical attention Avoid breathing concentrated vapors and sanding dust WEST SYSTEM epoxies have low VOC content but vapors can build up in unvented spaces Provide ample ventilation when working with epoxy in confined spaces such as boat interiors When adequate ventilation is not possible wear a NIOSH National Institute for Occupational Safety and Health approved respirator with an organic vapor cartridge Provide ventilation and wear a dust mask when sanding epoxy especially partially cured epoxy Breathing partially cured epoxy dust increases your risk of sensitization Although epoxy cures quickly to a sandable solid it may take up to two weeks at room temperature or elevated temperature post curing to reach published physical properties Avoid ingestion Wash thoroughly after handling epoxy especially before eating If ep oxy is swallowed drink large quantities of water DO NOT induce vomiting Because hardeners are corrosive they can cause additional harm if vomited Call a physician im mediately Refer to First Aid procedures on the Material Safety
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