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4. Remove or shape excess adhesive that squeezes out of the joint as soon as the joint is se- cured with clamps. An 804 Reusable Mixing Stick or a wooden mixing stick with one end sanded to a chisel edge is an ideal tool for removing the excess (Figure 5-11). Single-step bonding Single-step bonding is applying the thickened epoxy directly to both bonding surfaces without 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 mix- ture, the more it can penetrate the surface) and that you do not use this method for highly-loaded joints or for bonding end grain or other porous surfaces. 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 hon- eycomb core material. Vacuum bagging is the ideal clamping method for laminating a wide range of materials. Through the use of a vacuum 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. See page 1. 5.4.3 Bonding with fillets 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, 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 5.4.2 Bonding. 2. Shapeandsmooththesqueezed-outthickepoxyintoafilletbydrawingaroundedfilleting tool (804 Mixing Stick) along the joint, dragging excess material ahead of the tool and leav- ing a smooth cove-shaped fillet bordered on each side by a clean margin. Some excess filleting material will remain outside of the margin (Figure 5-12). Use the excess material to re-fill any voids. Smooth the fillet until you are satisfied with its appearance. An 804 Mix- ing Stick will leave a fillet with about a 38" radius. For larger fillets, an 808 Flexible 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 de- sired size of fillet. For longer or multiple fillets, empty caulking gun cartridges or disposable 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. Using WEST SYSTEM® Epoxy 41 5PDF Image | Vacuum Bagging Techniques 002150
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