Mold Resurfacing

8/13/2019 Mold Resurfacing

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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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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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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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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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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/

Mold Resurfacing

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