Post on 04-Jun-2018
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COMPOSITE MOLD RESURFACINGWITH DURATEC AND AQUA-BUFF PRODUCTS
Hawkeye Industries Inc.
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Repair vs. Resurfacing
Chips, cracks and gouges on otherwise sound
molds can be repaired with Duratec Mold
Repair Putty, sanded and polished to a
flawless surface. If however, a mold hasnumerous defects and an overall dull and
rough finish, resurfacing is the appropriate
course of action.
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Duratec and Aqua-Buff Products
for Polyester and VE Mold Resurfacing
Duratec Vinyl Ester Mold Repair
Putty (if needed)
Duratec Polyester Surfacing
Primer
Duratec Vinyl Ester Hi-Gloss
Topcoat
Duratec Thinner
Aqua-Buff Tuff-Stuff Rapid Cut
Compound
Aqua-Buff GlossMaster Polish
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Prepping the Mold
The surface should be clean, dry and free from oil,grease, wax or other contaminants.
Ambient temperatures should be in excess of 60F,16C to ensure a rapid and complete cure.
Time calculations are based on temperatures of77F, 25C.
Prior to sanding the surface all mold releases mustbe removed using the chemical stripperrecommended by the mold release manufacturer.
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Prepping the mold
Starting from a
correctly shaped and
dimensionally stable
mold, sand the entire
surface with a coarse
sandpaper (80- or
120-grit), making sureto feather in puttied
and filled areas.
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Prepping the mold
Wipe the
sanded
surface with
acetone and
a clean white
towel. Do not
use a tackrag.
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Product preparation
Thoroughly stir Duratec Polyester Surfacing
Primer prior to catalyzing.
Due to the rapid gel time of the primer,mix only the amount that can be applied
within 16-18 minutes @77F, 25C.
(Higher temperatures yield a shorter pot
life and gel time, while lower temperaturesyield a longer pot life and gel time.)
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Product preparation
Catalyze at 2 percent with
mekP catalyst (20 cc per quart).
The primer can be thinned up to
10 percent if necessary to
achieve a fine spray. Thin with
Duratec Thinner or Methyl Ethyl
Ketone solvent aftercatalyzation.
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Spraying the mold
We recommend a gravity-
feed, siphon or pressure
pot system with a 2.5
millimeter tip and 38-42
psi of line pressure (12-15
psi in a pressure pot).
Apply a "tack coat" to theentire surface and allow it
to flash for 2 minutes.
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Spraying the mold
Follow with wet passes,
slowly building to the
desired thickness of 15
mils (375 microns)unless the surface is
unusually rough and
requires a greater
build.
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Spraying the mold
Heavier thickness can
be achieved by
repeating the
process immediately
after gel has
occurred.
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Allowing the mold to dry
The primer will
be dry to the
touch in 1-4hours, depending
on thickness and
temperature, and
ready to sandwithin 2-4 hours
at 77F, 25C.
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Sanding the mold
Dry sand the entire
surface with 80- or
120-gritsandpaper.
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Cleaning the mold
Wipe the surface with
acetone and a clean white
cloth. Do not use a tack rag.
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Topcoating the mold
To achieve the
ultimate gloss
and surfacedurability apply
Duratec Vinyl
Ester Hi-Gloss
Coating.
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Product Preparation
Thoroughly stir Duratec
Polyester Hi-Gloss Coating
prior to catalyzing. Due to the
rapid gel time of the coating,mix only the amountless
than a quartthat can be
applied within 15-18 minutes.
(Higher temperatures yield a
short pot life and gel time
while lower temperatures
yield a longer pot lie and gel
time.)
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Product Preparation
Catalyze at 2 percent
with low hydrogen
peroxide mekP catalyst
(20 cc per quart). Thin
after catalyzing with
Duratec Thinner if
needed to create a finespray.
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Spraying the topcoat
We recommend a gravity-feed, siphon or pressure potspray system with a 1.8
millimeter tip and 38-42 psiof line pressure (12-15 psiwith pressure pot).
(This work was done with a
Binks M1G cup gun and a2.2 millimeter tip at 40pounds of line pressure.)
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Spraying the topcoat
Apply a "tack coat" to the
entire surface and allow it
to flash for 2 minutes.
Follow with a mist coat and
two-three wet passes to
achieve a thickness of 15-
20 mils, 375-500 microns,over the sanded surface.
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Curing the topcoat
Allow the topcoat to cure to a
dry-to-the-touch condition
(4-8 hours at 77F, 25C).
If properly applied there will
be very little orange peel or
dry overspray.
The topcoat must be sandedand polished to achieve full
cure and best performance.
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Sanding the topcoat
When the topcoat has cured,begin with the finestsandpaper that will takedown the surface profile andsand the surface, workingthrough the grits, up to 1000-grit paper.
Note: For best results, after sanding, wait atleast overnight at 77F, 25C before
compounding and polishing the surface. Forexceptionally large molds that require twodays or more days of sanding, no waiting isnecessary.
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Compounding the mold
Remove scratches
with Aqua-Buff
Tuff-Stuff Rapid
Cut Compound.We recommend
an industrial
style buffer,
operating at
2200 rpm.
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Compounding the mold
Apply Tuff-Stuff in
three (3) quarter-size
mounds per square footto the mold surface. (If
the compound builds up
on the pad reduce the
amount applied.)
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Compounding the mold
Using a professional
buffer, buff with a wool
or wool-blendcompounding pad. The
surface should look wet.
If not, apply more Tuff-
Stuff.
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Compounding the mold
Buffing speeds will vary
depending on individual
buffing styles, butbuffing at too high of a
speed (greater than
2200 rpm) can cause
surface burning.
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Compounding the mold
Buff the surface with
Tuff-Stuff until the haze
is eliminated and allsanding scratches are
removed.
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Polishing the mold
Polish the mold
with Aqua-Buff
GlossMasterPolish.
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Polishing the mold
ApplicationApply
GlossMaster in three (3)
quarter-size moundsper square foot to the
surface that is to be
polished. (If the polish
builds up on the pad,
reduce the amount
applied.)
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Polishing the mold
Using a professional
buffer, polish with a soft
polishing pad.
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Polishing the mold
While polishing, thesurface should look wet.If not, add more
GlossMaster.Polishing speeds willvary depending onpolishing styles, but wehave found that speedsof 2400 rpm work well.
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Polishing the mold
To obtain the highest
possible gloss finish, you
may follow with anegg-crate foam
polishing pad. You will
want to use a water
mister bottle to keep
the surface wet.
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Polishing the mold
Polish until the haze is
eliminated and you
have a smooth, glossyfinish.
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Mold Resurfacing
To order Duratec and
Aqua-Buff products
contact your local
distributor. For more information
about the full line of
our products, visit our
web site at
www.duratec1.com
http://www.duratec1.com/http://www.duratec1.com/