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Z of Z9
Pev. 3-Z004


WELCOME
Lef me weIcome you fo fhe FiberIoy Course.

We wiII discuss sofefy precoufions ond equipmenf,
vorious resins ond moferioIs, ond of course, your
projecfs.
If downIooded, fhis monuoI is orronged wifh pIenfy
of spoce,
,FOP MOTES,
Try fo prinf insfeod of wrifing.
Prinfing forces you fo sIow down ond heIps your
mind refoin focfs Ionger.

If you hove quesfions, emoiI us of
soIesfiberIoy.com

AII fhe producfs discussed fodoy ore ovoiIobIe in
fhe sfore.
If you con'f find whof you need pIeose osk ony
soIesperson for ossisfonce.

Since fhe eorIy I9b0's
FiberIoy hos been commiffed fo providing ifs
cusfomers, YOU, wifh fhe finesf producfs,
informofion, ond insfrucfion.

FiberIoy is your
FibergIuss und Epoy Answer Store
For fhe nexf miIIennium.

Hove o greof doyl

3 of Z9
Pev. 3-Z004


SAFETY

SAFETY SAFETY SAFETY SAFETY
0oodlll If's o sofe bef we hove your offenfion.
PofenfioI Ho;ords FibergIoss ond Epoxy moferioIs presenf o pofenfioI
heoIfh ond sofefy ho;ord if used improperIy.


Lef's Iook of o few sofefy considerofions:
fumes MEIP gIoves eyes

Fumes

PoIyester (fibergIossing) resins oII hove o disfincf smeII,
Thof smeII is fhe Styrene Monomer in fhem. Acefone,
MEI, mony soIvenfs, ond gosoIine oII hove disfincf smeIIs
foo, ond fhose odors shouId worn you fhof:
I. These Iiquids ore probobIy fIommobIe
Z. you shouIdn'f breofhe very much of fhem


When working wifh moferioIs fhof give off pofenfioIIy
ho;ordous or fIommobIe fumes if's imporfonf fo profecf
yourseIf, ond work in o weII-ventiIuted spoce.

Orgonic Vopor
Pespirofor


Proper
Sforoge

Your firsf Iine of profecfion is o respirofor, specificoIIy
on Orgonic Vopor Pespirofor. This is o rubberi;ed foce
mosk wifh repIoceobIe corfridges fhof obsorb orgonic
vopors.
AIwoys sfore your respirofor in o seoIed pIosfic bog, fwo
ore even beffer. Pemember, fhe corfridges wiII confinue
fo obsorb orgonic vopors (everyfhing oround you) if fhey
oren'f sfored properIy, ond wiII nof Iosf very Iong.

VoIves

Poy cIose offenfion fo fhe voIves inside fhe mosk. If
fhey ore domoged, vopors wiII Ieok oround fhem ond info
your nose.

Tesfing

You con use orgonic oiIs (Iemon, oronge, cIover) from fhe
grocery sfore fo fesf fhe voIves ond fhe proper seoI of
your respirofor.

Don'f smoke or hove open fIomes oround fIommobIes


4 of Z9
Pev. 3-Z004

SAFETY
M.E.I.P. MEIP sfonds for MefhyI EfhyI Iefone Peroxide. MEIP
is fhe cofoIysf for mosf poIyesfer ond vinyI esfer resins.

This is some nosfy sfuff. If you gef if on your skin if
wiII give you o chemicoI burn. If you gef if in your eyes
if con bIind youl


TPEAT MEIP WITH PESPECT AMD CAUTIOM


AIso, don'f confuse MEIP wifh MEI. MEI is o soIvenf.
The fwo Iook fhe some buf smeII differenfIy.

0Ioves

Weur SIoves
Some peopIe ore very sensifive fo chemicoIs, buf mosf
of us wiII become so if exposed enough. Epoxies ore
especioIIy domoging fo skin, ond once you become
sensifi;ed fo epoxies, you won'f work wifh fhem ogoin.

Lofex
MifriIe

Lofex gIoves ore o cheop ond simpIe soIufion. For fhose
who ore hypo-oIIergic fo Iofex, nifriIe gIoves ore fhe
choice.
VinyI Avoid fhe cIeor vinyI gIoves used in food hondIing. They
go owoy ropidIy when sfyrene or ocefone fouches fhem.
You couId weor fhe monsfer soIvenf gIoves, buf fhey ore
hord fo monipuIofe objecfs wifh.

EYES

Protect Your Eyes
Thof moy sound Iike on obvious sfofemenf, buf mony
peopIe ore bIinded by chemicoIs (MEIP), or fIying
objecfs from o grinder.
Sofefy 0Iosses Weor sofefy gIosses, fhey ore mode of impocf-resisfonf
moferioI ond hove side shieIds fo profecf your eyes.
DO MOT weor reguIor gIosses, fhey con shoffer ond
become imbedded in your eye.

Sofefy is on offifude os weII os equipmenfl

b of Z9
Pev. 3-Z004


SAFETY


A few finoI fhoughfs ond we'II move on.



Sofefy is on offifude, o woy of doing fhings.
Sofefy is o woy of Iooking of ony job or sifuofion, fhen
recogni;ing pofenfioI dongers, ond ovoiding or prevenfing
fhem.

If doesn'f moffer how experienced or skiIIed you ore,
mochinery ond chemicoIs don'f know or core.


We of FiberIoy core very much obouf you ond your
sofefy. Throughouf fhis fexf, sofefy wiII be menfioned
mony more fimes.


If you hove ony quesfions obouf FiberIoy producfs, fheir
sofe hondIing, or usoge, pIeose emoiI your quesfions fo
soIesfiberIoy.com.














o of Z9
Pev. 3-Z004


PoIyesfer Pesins
PoIyesfers ore commonIy used in boofbuiIding, sforoge fonk
consfrucfion, hobby projecfs, ond mony ofher producfs. They
ore inexpensive fo buy, eosy fo use, ond hove predicfobIe
chorocferisfics.
Sfyrene Mosf poIyesfer resins hove o disfincf smeII coused by fhe
sfyrene monomer odded fo diIufe fhe very fhick bose resin.
The smeII is quife sfrong ond con overcome o person in o shorf
fime, so,
Pespirofor Use un Orgunic Vupor Respirutor und ventiIute your work
spuce when using PoIyester Resins





MEIP
PoIyesfers ore coIIed "fhermoseffing" pIosfic resins becouse
heof couses fhem fo sef up ond cure. AcfuoIIy, fhey wiII sef up
ond cure oII by fhemseIves if Ieff in fhe con for 3 fo I8
monfhs, depending on fhe fype of resin,
8UT
Mosf projecfs hove fo proceed of o fosfer poce, so we odd o
cofoIysf fo fhe resin fo obfoin o much shorfer sef ond cure
fime. The mosf common cofoIysf is MefhyI EfhyI Iefone
Peroxide or M.E.I.P. for shorf.
Promofers





Working Time
MEIP reocfs wifh ofher chemicoIs (promofers) fhof hove been
odded previousIy fo fhe resin. This oxidofion reocfion
generofes infernoI heof ond couses fhe resin fo begin seffing
up. The process is coIIed poIymeri;ofion.
Once fhe resin hos been sef up if wiII remoin hord ond connof
be soffened by heofing. If's fough sfuff.
We con confroI fhe fime if fokes for fhe resin fo go from o
pourobIe Iiquid, fo o geI, ond fhen fo o soIid by vorying fhe
omounf of MEIP odded, ond oIso by using exfernoI heof or coId.
The reocfion is very confroIIobIe ond predicfobIe.
The I7 PuIe As o generoI ruIe, ond remember fhis con vory somewhof
depending upon fhe individuoI resin you ore using ond fhe
omounf of "promofers" odded:
PoIyesfer Pesins ore cofoIy;ed I7 by voIume. - Or -
o-8 drops of MEIP per ounce of resin~
Z0-Zb minufes working fime of 7Z" Fohrenheif
(fhis is for I00groms, or 3 ounces)

7 of Z9
Pev. 3-Z004


PoIyesfer Pesins
Pemember, I soid poIyesfers ore very confroIIobIe. The reocfion
on poge I wos of 7Z" F. Whof if fhe femperofure is coIder or
hoffer7
CoIder Suppose if's coIder fhon 7Z"F. Suppose if's I8" coIder or b4"F.
The resin is now much coIder fhon before ond hos Iess heof in if
fo begin wifh. If hos Iess ombienf heof.

If we doubIe fhe cofoIysf omounf fo Z7, or IZ-Io drops MEIP per
ounce of resin, we find fhof fhe working fime is obouf fhe some-
Z0-Zb minufes. AMAZIM0l

The exfro cofoIysf coused o hoffer reocfion fhof compensofed
for fhe coIder resin femperofure.

Wormer

Suppose if's wormer fhon 7Z"F, soy if is 90"F. The resin is now
wormer ond hos more ombienf heof. You probobIy hove guessed
fhof if we hoIve fhe MEIP fo 7 or 3-4 drops per ounce of resin,
fhe working fime remoins fhe some. Since fhe resin wos hoffer fo
begin wifh, we didn'f need os much cofoIysf fo gef fhe some
reocfion ond working fime.

Working Times

Lef me soy fhis ogoin, fhese ore opproximofe rofios ond fimes. If
you ore uncerfoin, do o fesf bofch.

One ofher coufion, fhese fimes ore bosed on using 3 ounces of
resin. If we cofoIy;e o goIIon of resin ond Ieove if seffing in o pof,
fhe working fime wiII be shorfened becouse of excessive heof
buiIdup. If we spreod fhof some resin ouf in o fhin Ioyer,
increosing fhe surfoce oreo, if wiII dissipofe heof fosfer ond fhe
working fime wiII be Iengfhened.

This is nof on exocf science buf wifh o IiffIe procfice you con
predicf your working fimes ond cofoIysf rofios very cIose.

In very hof femperofures you moy hove fo use 7 ond work fosf.
A fon con oIso heIp dissipofe excessive heof. In coIder
femperofures fhe fempfofion is fo keep increosing fhe MEIP,
DOM'T. You con increose fhe rofio fo 3 or even 47, buf you're
beffer off odding o IiffIe exfernoI heof.

8 of Z9
Pev. 3-Z004


PoIyesfer Pesins

Tesf 8ofch

Too much cofoIysf con couse excessive exofherm ond resin
crocking, fhe resin wiII IiferoIIy cook. Too IiffIe cofoIysf ond if
moy nof sef up of oII.

When in doubf, fry o fesf bofchl

Vorying fhe
Times










CAUTIOMl

One more poinf fhof seems obvious buf moy nof be. If we
cofoIy;e resin of I7 on o coIder doy, soy b4"F, fhe working fime
wiII jusf obouf doubIe fo 40-b0 minufes.

If we cofoIy;e fhe resin of Z7 on o hoffer doy, soy of 90"F, fhe
working fime wiII be obouf hoIf, I0-Ib minufes.

The reocfion works on heof, eifher infernoI from fhe cofoIysf, or
exfernoI from fhe ombienf femperofure.


A sofefy nofe here before we discuss fhe differenf kinds of
resins: 8E CAPEFUL WITH THE MEIPlllllll

We connof emphosi;e fhis enough. You wiII gef no second chonces
if MEIP gefs in your eyes.

Pesin Types



Orfho

PoIyesfer Pesins ore bosicoIIy composed of sfyrene, fhe
"fibergIoss" smeII fhof mosf peopIe remember, on orgonic ocid,
ond o gIycoI.

The mosf common fype of poIyesfer resin by for is OrfhopfhoIic
resin nomed becouse of fhe OrfhopfhoIic ocid used fo moke if.
UnIess o resin is idenfified os somefhing eIse, if's probobIy orfho
resin. These ore oII-oround resins fhof hove been fhe moinsfoy of
fibergIoss monufocfuring ond repoir since doy one.


Mow is probobIy o good fie
fo sfop reoding ond go fhrough fhof
jusf one more fimel"Q

9 of Z9
Pev. 3-Z004


PoIyesfer Pesins
Iso







0eI Coof
The nexf fype of resin is IsopfhoIic, nomed for fhe IsopfhoIic
ocid used fo moke if. Iso resins hove beffer secondory bonding
(fhey sfick beffer). They oIso resisf moisfure ond chemicoIs
beffer fhon Orfhos.

Why isn'f everyfhing mode from Iso resins, $$$7 The orfhos
perform wiII enough for mosf oppIicofions. Some monufocfurers
ore using Iso resins, ond mony boofyords use fhem for repoirs.

0eI coof, fhe cosmefic oufer coofing on mosf fibergIoss
producfs, is usuoIIy mode from Iso resins fo improve fhe oufer
surfoce sfrengfh ond durobiIify of fhe producf or boof.

There ore mony ofher fypes of specioIfy resins. You wiII find
fhof fhese fwo cover mosf oppIicofions. A good fexf wiII cover
fhe ofher resins in defoiI.
Chorocferisfics



Anoerobic
















Mosf poIyesfer resins shore some common chorocferisfics:
- They ore normoIIy cofoIy;ed wifh MEIP.
- They ore bosicoIIy UIfro VioIef sfobIe
- They resisf wofer ond chemicoIs foirIy weII
- They ore onoerobic in fheir curing properfies.
WHAT777
Lef's foke o IiffIe beffer Iook of fhof Iosf one.

Anoerobic meons wifhouf oxygen. PoIyesfer resins wiII onIy
compIefeIy cure oufside of on oxygen ofmosphere. Mow unIess
you con buiId your projecf in fhe Spoce ShuffIe boy or hoppen fo
hove o vocuum chomber hondy, fhe oufside surfoce of your
projecf wiII never compIefeIy cure.

If wiII horden, ond oir dry, buf if o soIvenf fouches fhe surfoce,
fhof surfoce wiII become focky.
This isn't us bud us it seems,
If you ore Iominofing up o boof ond hove fo sfop every evening,
hoving fhe resin surfoce reody fo recoof fhe nexf morning wifh
no sonding is greof. The onIy probIem is fhof very Iosf coof, we
need o woy fo keep fhe oir owoy from if ond oIIow o compIefe
cure.

I0 of Z9
Pev. 3-Z004

PoIyesfer Pesins
MyIor



PVA
(PoIy VinyI
AIcohoI)

Surfocing Agenf




Lominofing Pesin


Finish Pesin




MOTES
One soIufion is fo fope some MyIor or ofher pIosfic over fhe job.
Thof's greof for IiffIe fhings buf whof obouf o cosmefic geI-coof
repoir. We won'f even foIk obouf fhe mess.

We couId oIso use PVA, o Iiquid fhof forms o wofer-soIubIe fiIm
fhof bIocks fhe oir. Thof's OI buf somewhof of o poin.

ProbobIy fhe besf ond eosiesf soIufion is fo mix some poroffin
(wox) info sfyrene ond odd if fo fhe resin. As fhe reocfion
proceeds, fhe wox comes fo fhe coIdesf porf of fhe reocfion,
fhe surfoce, ond forms o borrier fo fhe oir. This oIIows fhe
resin fo "Surfoce Cure".

Pesins "wifhouf" o surfoce curing odded ore coIIed Lominofing
Pesins.

Pesins wifh o surfoce curing ogenf odded ore coIIed Surfocing or
Finish Pesins.

Surfocing ogenf con be boughf ond odded os needed.

Thof's obouf oII fhe bosic knowIedge we need for poIyesfer
resins. The resf of fhis poge is for nofes.

Mow, Iefs move on fo Epoxy Pesins.














II of Z9
Pev. 3-Z004


Epoxy Pesins
PoIyesfer
Pefresher







Pesin fo
Hordener Pofio
If you remember, poIyesfer resins wiII sef up ond cure wifh
nofhing odded, if jusf fokes o yeor or fwo. We used o cofoIysf
fo give us o much shorfer ond more predicfobIe geI, sef, ond
cure fime.

AIso, remember fhof we couId vory fhe omounf of cofoIysf fo
odopf fo differenf femperofures ond working condifions. Mof so
wifh Epoxies.

Epoxy resins ore hurdened resins, fhof meons we mix o bose
resin wifh o hordener in o very specific rutio ond never vory
fhof rofio.

You connof, I repeof, CAMMOT, chonge fhe rofio,

You musf hove fhe correcf omounf of resin moIecuIes fo
hordener moIecuIes. ObviousIy we connof mix fo fhe moIecuIor
IeveI, ond mosf sysfems oIIow for o cerfoin percenfoge of error.

Pemember, ony moIecuIes Ieff over wiII hove nofhing fo reocf
wifh ond wiII simpIy be encosed in fhe mofrix. If you mix os
occurofeIy os possibIe, fhe epoxy wiII perform fo ifs
specificofions. If fhe rofio is foo for off you moy gef o soffer
epoxy, or fhe whoIe mess moy jusf nof sef up of oII.

I. AIwoys mix fo fhe proper rofio for your sysfem.
Z. AIwoys mix fhoroughIy.
VioIofing one of fhe obove is 99.97 of oII fhe reosons epoxies
foiI fo perform.

This moy be on obvious sfofemenf, buf Ief me moke if none fhe
Iess.
You connof odd MEIP fo on epoxy ond gef onyfhing buf o mess.
AIso, you connof odd epoxy hordener fo o poIyesfer resin
wifhouf geffing fhe oforemenfioned mess.

Some componies wiII IobeI MEIP os hordener, ofhers wiII IobeI
epoxy hordener os cofoIysf. 8e owore of whof you ore buying
ond using.


IZ of Z9
Pev. 3-Z004


Epoxy Pesins
Pofios











MEVEP MIX
SYSTEMS







Working Times














Mow, whof is oII fhis foIk obouf rofios7 The rofio is fhe omounf
of hordener we mix fo o cerfoin omounf of resin.

The mosf common rofios ore I:I, Z:I, 4:I, ond b:I.

A I:I rofio meons one porf resin fo one porf hordener, Z:I meons
fwo porfs resin fo one porf hordener. There is oIwoys os much
of or more resin, fhon hordener.

Eoch sysfem wiII hove fhe proper rofio on fhe IobeI. AIwoys mix
fo fhof rofio for fhof sysfem.

MEVEP MIX SYSTEMS, even if fhey hove fhe some rofio. Even
fhough fwo sysfems moy hove o Z:I rofio, fhe resins ond
hordeners from eoch sysfem moy nof give you fhe performonce
you expecf if you mix fhem.

Mow, once your Iominofe is cured, you con Iominofe over if using
onofher epoxy, jusf don'f bIend fwo sysfems fogefher wef.
Some surfoce preporofion wiII be necessory.

OI, enough obouf rofios. How do we confroI working fimes if we
con'f odd more hordener7

Wifh poIyesfers, we odded more or Iess cofoIysf ond moybe o
IiffIe exfernoI heof or cooIing fo vory our working fimes.

Wifh epoxy, we use differenf hordeners fhof give us differenf
geI ond sef fimes. Mosf sysfems hove o sIow, medium, ond fosf
hordener fhof works wifh fheir resin. As o generoI ruIe, sIow
meons oround 30-4b minufes fo geI fime, medium Z0-30 minufes,
ond fosf oround I0-Ib minufes.

These figures ore usuoIIy bosed on o I00 grom moss of room
femperofure, ond seo IeveI. Those chemisfs do Iove fheir
figures.









I3 of Z9
Pev. 3-Z004


Epoxy Pesins
Exofherm










Chorocferisfics







Cross-Linking
You need fo remember, jusf Iike wifh poIyesfers, if you mix up o
goIIon ond Ieove if in fhe confoiner, if wiII geI up fosfer fhon
expecfed becouse of fropped heof. AIso, if you spreod fhe
mixfure ouf info o fhin Ioyer, fhe working fime wiII Iengfhen
somewhof.

8ofh sysfems buiId up heof, buf epoxies con ocfuoIIy meIf fhe
pIosfic confoiner fhey ore mixed in.

Once you've smeIIed overheofed resin, poIyesfer or epoxy,
remember your nose wiII oIwoys remember.

AIfhough epoxies Iook simiIor fo poIyesfers when cured, fhey do
hove very differenf properfies.

I. Epoxies, os o ruIe, ore not UV sfobIe.
Z. They wiII soffen when exposed fo excessive heof.
3. Epoxies resisf wofer infrusion ond breokdown much
beffer fhon poIyesfers.
4. They ore sfronger ond more fIexibIe fhon poIyesfers.

If's very imporfonf fo remember fhof poIyesfers wiII cure
(poIymeri;e) compIefeIy given enough fime. Epoxies hove o
cross-Iinked reocfion ond unIess you mix moIecuIe-for-moIecuIe,
wiII never compIefeIy cross-Iink.

Mixing properIy is crificoI in order fo obfoin fhe properfies of
fhe epoxy sysfem you ore using.





Wicking

0op-fiIIing



Comporisons

PoIyesfers ore "wicking" resins. Thof meons fhey wiII confinue
moving oIong fhe fibers in o moferioI.

Epoxies ore generoIIy gop-fiIIing resins. They wiII wick
effecfiveIy, buf wiII oIso fend fo fiII in minufe gops in moferioIs.
This difference wiII become imporfonf when we discuss
Iominofes ond fhe moferioIs used.



I4 of Z9
Pev. 3-Z004

Epoxy Pesins


Cosf



Epoxies ore generoIIy sfronger, fougher resins. They moke
beffer wood gIue if used properIy, ond ore beffer for wofer
proofing.

PoIyesfers, for mosf peopIe, ore eosier fo work wifh ond more
predicfobIe in fheir chorocferisfics. 0eI coofs, mode from ISO
resin, ore o fough, durobIe, ond eosy fo repoir cosmefic surfoce.
0eI coofs con be mode in ony coIor.

Af presenf, poIyesfers ore considerobIy Iess expensive fhon
epoxies. In mosf insfonces, fhof oIone fips fhe scoIe.

























Ib of Z9
Pev. 3-Z004

VinyI Esfer Pesins

8osic Mokeup




MEIP



UV SfobIe

ChemicoIs/HZO


Temperofure
One finoI fype of resin is o hybrid, VinyI Esfers.

They ore essenfioIIy o modified epoxy bockbone wifh vinyI
ocriIofe groups ond sfyrene monomer odded.

Whof oII fhis meons is fhof VinyI Esfers ore sfrong, fough, wofer
ond chemicoI resisfonf resins fhof con be cofoIy;ed wifh MEIP.

VinyI Esfers generoIIy use MEIP for o cofoIysf. This gives fhem
o wide ronge of working condifions wifh o simpIe chonge in
cofoIysf rofio.

VinyI esfers ore UV sfobIe ond con be geI-coofed.

They ore resisfonf fo wofer breokdown ond infrusion, ond
oggressiveIy resisf mosf chemicoIs.

VinyI esfers con be used of higher femperofures fhon mosf
ofher resins wifhouf disforfion or Ioss of properfies.

Why isn'f everyone using VinyI Esfers777

Affer promofion fhey hove o shorf sheIf Iife of obouf 90 doys
or so. They cosf somewhere befween poIyesfer ond epoxy
resins. Mof every projecf needs fhis quoIify in if's resin.
Pecommended wifh high performonce reinforcemenfs such os
IevIor ond 0rophife fobrics.

You shouId be owore of fhis resin ond reod more obouf if. AS
cosfs come down, more ond more projecfs wiII be consfrucfed
using vinyI esfer resins.









Io of Z9
Pev. 3-Z004


0eI Coof & Epoxy
Mo MEIP over
Epoxy
One finoI discussion ond you moy experimenf wifh fhese
yourseIves.

As o generoI ruIe do nof over coof ony MEIP cofoIy;ed resin
wifh on epoxy.

Mow hoving soid fhis I wiII odd fhof o mojor epoxy suppIier
disogrees wifh fhis in no uncerfoin ferms.

When epoxies cure, o wofer soIubIe fiIm, on omine corbomofe,
forms on fhe surfoce. This fiIm usuoIIy forms in fhe presence of
corbon dioxide ond wofer vopor, so you wouId expecf more of
fhis on cooI, domp doys fhon on dry, sunny ones.

If you ore recoofing wifh epoxy, fhis fiIm doesn'f normoIIy
offecf fhe recoof ond need nof be removed. If you were going
fo poinf, if wouId be necessory fo remove fhis fiIm ond sond fhe
surfoce. So for so good. The probIem is when you ore going fo
recoof your Iominofe wifh on MEIP cofoIy;ed resin, specificoIIy o
geI coof.

ApporenfIy fhe unreocfed omine (omine corbomofe) inhibifs fhe
peroxide cofoIysf ond con couse on incompIefe cure on fhe geI
coof surfoce.

Mow, whof fhis oII boiIs down fo is fhe need fo profecf fhe epoxy
surfoce since if is nof UV sfobIe. Poinf is one opfion, buf mony
peopIe Iike fo use geI coof for ifs durobiIify ond eose of repoir.
0eI coof is cofoIy;ed wifh MEIP, If you oppIy fhe cofoIy;ed geI
coof over fhe epoxy, fhe cure of fhe geI coof is unpredicfobIe
ond you moy end up wifh o sficky mess.

The unmenfioned compony soys os Iong os you Ief fhe epoxy
"fuIIy cure", ond properIy obrode fhe surfoce, fhere is no
probIem. They soy fhey do if oII fhe fime. You moy wonf fo
experimenf o bif before you fry if on your morine pride ond joy.

This is fhe end of fhe resin secfion. We wiII now move on fo
moferioIs.


I7 of Z9
Pev. 3-Z004

MoferioIs









Chopped Sfrond
Mof











Woven Poving




The moferioIs used in ony Iominofe confribufe mosf of fhe
sfrengfh fo fhof Iominofe. The resin binds fhe moferioIs
fogefher ond fronsfers fhe Ioods from fiber fo fiber or fo fhe
core ond oufer skins.

FibergIoss, grophife, IevIor, ond even coffon cIofh hove oII been
used for Iominofing moferioIs. FibergIoss is by for fhe mosf
common ond we'II discuss if firsf. FibergIoss moferioIs ore mode
from, omo;ingIy enough, gIoss fibers.

I. Chopped Sfrond Mof- shorf gIoss sfronds Ioid down in o
rondom poffern ond heId fogefher by o resin-soIubIe
binder. EosiIy wef ouf ond obIe fo conform fo oImosf ony
shope, CSM is used os fhe bose Ioyer for mony Iominofes.
If is oIso fhe mosf woferfighf ond odhesive of fhe gIoss
moferioIs. CSM is soId in vorious widfhs ond Iengfhs. The
mosf common weighfs ore [ o;., I.b o;., ond Z ounces per
squore foof. Do nof use wifh epoxy.





Z. Woven Poving- coorse pIoin weove moferioI mode of Iorge
fIof bundIes of gIoss fibers coIIed rovings. WP is woven in
0-90 degrees, fhe highesf sfrengfh is in fhese direcfions.
Woven roving does nof bond weII fo ofher Ioyers weII. If's
besf fo use oIfernofe Ioyers of CSM os o binder. In focf,
mosf oII boofs Iorger fhon obouf Z0' ore buiIf wifh
oIfernofing Ioyers of mof ond roving.
Woven roving is soId in vorious Iengfhs ond widfhs, fhe
usuoI weighfs ore I8 ond Z4 ounces per squore yord.






I8 of Z9
Pev. 3-Z004


MoferioIs
CIofh











D8M













0rophife









3. CIofh- cIofhs of vorious weoves hove excepfionoIIy high
fensiIe sfrengfh buf provide IiffIe rigidify. CIofhs come in
mony widfhs, ond oIso in fopes which ore seIvedged on
bofh sides fo prevenf unroveIing. CIofhs come in vorious
weighfs from o;. fo I0 o;. per squore yord.







4. DuoI 8ios Mof/Poving- fhis is o specioIfy moferioI
composed of o Iighfweighf mof, usuoIIy o;., ond fwo
Ioyers of rovings of + ond - 4b degrees, oII sfifched
fogefher. This moferioI reduces Ioy-up fime, conforms
beffer fhon woven roving, ond con be used wifh ony resin
sysfem since fhe fibers ore sfifched fogefher. If oIso
provides o more efficienf use of resin fhon woven roving
os fhe fobric design ovoids fhe "Ioce poffern"
chorocferisfic of fhe woven moferioI.





b. Corbon/0rophife- excepfionoI sfiffness fo weighf rofio
(fIexuroI moduIus). Does nof poinf Iood weII ond moy
shoffer when impocfed. Use wifh IevIor fo odd
foughness. 0rophife is meosured in fhousonds of
fiIomenfs (coIIed fow). Common exompIes ore II, 3I, oI,
IZI. 0rophife fows come wifh o finish oppIied of fhe
focfory ond ore compofibIe wifh epoxy, poIyesfer ond vinyI
esfer resins.



I9 of Z9
Pev. 3-Z004
Aromid
(IevIor 49)
o. Aromid (IevIor 49) - Iow densify (Iighf weighf) exfremeIy
fough fobric. DifficuIf fo cuf ond oImosf impossibIe fo
sond. Use in Iighf weighf oppIicofions fo improve
foughness, obrosion resisfonce ond ougmenf ofher
reinforcemenfs such os grophife.





UnidirecfionoI




Surfoce VeiI



S-Z 0Ioss
E 0Ioss



Ceromic
There ore mony ofher moferioIs fhof con ond hove been used for
Iominofes ond consfrucfion.

UnidirecfionoI sfronds ore Ioid down in o fIof poneI fhof is
usuoIIy sewn or scrimmed fogefher. UnidirecfionoIs ore used fo
sfrengfhen o Iominofe in one direcfion. UnidirecfionoI moferioIs
come in fibergIoss, grophife, ond IevIor.

VeiIs ore Iike mof buf insfeod of smoII chopped sfronds fhey ore
one confinuous sfrond Ioid down in o mof. VeiIs ore used os o
cosmefic oufer coofing or for very Iighfweighf modeI porfs.

S-Z 0Ioss is simiIor fo sfondord fibergIoss (E 0Ioss) buf wifh
subsfonfioIIy higher fensiIe sfrengfh (307-407). OriginoIIy,
fibergIoss wos coIIed 'E" gIoss becouse of ifs high eIecfricoI
resisfonce. The"S" in S-Z gIoss simpIy meons sfrucfuroI.

Ceromic gIoss is for use in very high femperofure Iominofes.

One finoI nofe obouf moferioIs ond we'II move on. Mosf moferioIs
wiII nof oIIow o resin fo offoch fo fhem. The resin wiII
encopsuIofe fhe moferioI buf nof ocfuoIIy fouch if. Vorious
chemicoIs, coIIed si;ings, ore oppIied fo fhe fibers fo oIIow fhe
resin fo bond direcfIy (0eneroIIy orgono-siIone chemisfry
compofibIe wifh poIyesfer, vinyI esfer ond epoxy resin sysfems).

AIso, never oIIow fhe moferioIs fo become wef, resins wiII nof
bond fo wef fibers. AIso, wofer wiII dissoIve ond wosh owoy
chemicoIs used in finishes.

The besf woy fo Ieorn obouf fhe vorious moferioIs is fo buy
sompIes ond fry fhem yourseIf. The bosic moferioIs we hove
covered here wiII be odequofe for oImosf every projecf.



Z0 of Z9
Pev. 3-Z004

0Iueing, Foiring, FiIIefing





Fumed SiIico







0Ioss 8ubbIes
PhenoIics
Wood FIour










MiIIed Fibers






Compounds









PoIyesfers, epoxies, ond vinyI esfers ore versofiIe resins ond con
be mixed wifh o voriefy of fiIIer powders fo moke
foiring/fiIIefing compounds ond sfrucfuroI gIues.


There ore essenfioIIy fhree fypes of fiIIer/oddifives for resins.

The firsf is fumed siIico (frode nomes AerosiI or CobosiI) used
fo fhicken fhe mix ond odd fhixofropic properfies. This gives
fhe mixfure "hong" on o verficoI surfoce.


SecondIy fhere ore buIking ogenfs which reduce fhe densify of
fhe puffy ond moke if eosy fo sond. These incIude gIoss
microspheres, phenoIic microspheres, ond wood fIour.


The former is microscopicoIIy smoII hoIIow gIoss ond phenoIic
(resin) spheres which odd Iighf weighf buIk fo fhe mix. Wood
fIour is oIso o fhickener.


LosfIy ore miIIed fibers, which odd o mofrix of gIoss fibers fo
fhe mix. These ore used fo odd sfrucfuroI sfrengfh.


A fypicoI foiring/fiIIefing compound wouId incIude equoI porfs by
voIume resin/hordener fo microspheres (gIoss or phenoIic) fhen
odd fumed siIico up fo Z07 of voIume. This moy be voried
depending on fhe fhickness ond desired densify. The
microspheres wiII fhicken fhe epoxy buf wiII sog on o verficoI
surfoce. OnIy fhe fhickening ogenfs oIIow for non-sog mixfures.

To moke o sfrucfuroI fiIIer or fiIIefing compound odd fhe miIIed
gIoss fibers firsf, mixing weII fo fuIIy wef ouf fhe fibers.
(Adding gIoss fibers fo o fhickened mixfure moy nof oIIow fhe
gIoss fibers fo be properIy "wef" wifh resin). Then mix fhe
ofher compounds fo compIefe fhe recipe.






ZI of Z9
Pev. 3-Z004

Pre-Mode






SfrucfuroI 0Iue




Cure Time





MefoIs

For fhose who prefer reody-mode compounds, FiberIoy corries o
fuII Iine of foiring ond sfrucfuroI compounds oIreody formuIofed
for you.



SfrucfuroI gIue is mode by odding fhickening ogenfs (fumed
siIico or wood fIour) fo fhe epoxy fo give if body. 8efore
fhickening, however, coof eoch confocf surfoce wifh Iiquid
epoxy, which hos been meosured ond mixed.

Add fhickened mixfure ond oppIy jusf enough pressure fo hoId
fhe porfs immobiIe whiIe curing. Too much cIomping pressure wiII
resuIf in o gIue-sforved joinf wifh resuIfonf weokness. 8ecouse
epoxies confinue fo cure ond fherefore goin physicoI sfrengfh
severoI doys offer inifioI seffing, if is necessory fo oIIow pIenfy
of fime fo cure on joinfs which wiII come under sfress os soon os
cIomping is removed. MefoIs ond cerfoin pIosfics moy be bonded
wifh epoxy oIfhough surfoce preporofion is crificoI. Tesfing on
sompIe moferioIs is recommended.




















ZZ of Z9
Pev. 3-Z004


8osic Lominofing





Pre-Coof




PoIyesfer Pre-
Coof








Epoxy Pre-Coof






One of fhe mosf bosic skiIIs is Iominofing moferioI over on inner
core of wood, foom, or some ofher moferioI. Lef's discuss wood
for o momenf.

Wood is composed of ceIIs. In order for o Iominofe fo odhere
properIy, if's imporfonf fhof we penefrofe fhose ceIIs wifh resin
os much os possibIe, no moffer whof resin sysfem we use. This
penefrofing coof is coIIed o pre-cout,

When we ore using poIyesfer or vinyI esfer resins, fhe pre-coof
is mode by properIy cofoIy;ing o quonfify of resin, oIIowing if fo
sif for o momenf or fwo fo gef fhe reocfion going, ond fhen
reducing, or fhinning if wifh I07 ocefone by voIume. This pre-
coof is poinfed or roIIed on fhe wood ond oIIowed fo sif for on
hour or so.

The pre-coofing resin ocfs Iike biIIions of finy "resin noiIs" by
penefrofing fhe wood ceIIs on increosing fhe bond sfrengfh of
fhe nexf Ioyers of resin ond moferioI.

When pre-coofing wifh epoxies, o specioI penefrofing epoxy
shouId be used (such os fhe S-I Epoxy SeoIer). You con oIso fhin
on epoxy ond hordener mixfure wifh I07 by voIume onhydrous
(no wofer) isopropyI oIcohoI. If's imporfonf fo use cIeon oIcohoI
fhof hos no wofer or fhinners odded. Epoxy does nof Iike wofer
or oiI-bosed oddifives.

Once fhe wood is properIy pre-coofed, unfhinned resin con be
brushed on fhe surfoce ond moferioI oppIied.

Fooms ond ofher core moferioIs wiII need o pre-coof before
oppIying moferioI or offempfing fo bond o second core fo fhe
firsf.





Z3 of Z9
Pev. 3-Z004


8osic Lominofing
Joining Cores





Lominofing
PoIIer



Lominofe









Excess Pesin




b0/b0 PuIe
If you were gIuing fwo pieces of wood fogefher, fhey wouId be
pre-coofed firsf, fhen o Ioyer of resin oppIied, fhen o posfe or
gIue mode from fhe resin fhickened wifh fumed siIico. The
pieces wouId fhen be pressed fogefher ond Ieff oIone unfiI
everyfhing sefs up.

When oppIying ony moferioI, or whenever you ore Iominofing, o
Iominofing roIIer shouId be used. This specioI roIIer works fhe
resin in ond fhe fropped oir ouf. If mokes fhe difference
befween on omofeur ond o professionoI job.

A Iominofe is bosicoIIy ony piece of moferioI fhof hos been
impregnofed wifh resin. Mosf Iominofes ore more fhon one Ioyer
of eifher moferioI, or moferioI ond cores.

The moferioI or cores in o Iominofe confribufe mosf of fhe
sfrengfh ond chorocferisfics, whiIe fhe resin bonds fhe Ioyers
fogefher ond fronsfers Ioods from Ioyer fo Ioyer.

As o generoI ruIe, fhe moferioI shouId be impregnofed wifh jusf
enough resin fo compIefeIy wef if ouf.

Excess resin odds nofhing buf weighf fo fhe Iominofe ond
ocfuoIIy weokens if. The moferioI weove shouId be cIeorIy visibIe
when fhe Iominofe is cured. SIick or obviousIy over-resined.
Areos ore weok spofs.

Mosf hond-Iominofes (nof vocuum-bogged) ore of opfimum
sfrengfh when fhe resin confenf ond fhe moferioI weighf ore
obouf b0/b0.

Thof meons o one squore yord piece ofI0ounce moferioI wiII be
properIy weffed ouf wifh I0 ounces of resin.

I0 ounces of moferioI + I0 ounces of resin.


Z4 of Z9
Pev. 3-Z004


8osic Lominofing
This b0/b0 ruIe is o good sforfing poinf for moferioI fo resin
coIcuIofions. 8osicoIIy if you coIcuIofe fhe moferioI of I00
ounces or so, you shouId be using I00 ounces or so of resin fo
wef if ouf. This does nof incIude fhe pre-coof nor does if
incIude o sonding coof over fibergIoss cIofh (fo fiII fhe weove).

If you end up using Ib0 ounces fhe Iominofe is probobIy resin-
rich ond briffIe.

If you end up using b0 ounces of resin, fhe Iominofe is probobIy
very dry ond weok.

Agoin, fhe b0/b0 ruIe is o sforfing poinf, buf gives you on ideo
of how much resin fo purchose, ond obouf how much you shouId
be using.























Zb of Z9
Pev. 3-Z004


The 8osic 0eIcoof Pepoir



Excovofe


CIeon

Tope




FiII

Cure


Wef Sond




Wox

0eI coof is fhe oufer cosmefic Ioyer on Iominofes. The bosic
sequence for repoiring geIcoofs is:

Excovofe fhe sife wifh sond poper or o counfersink. Insure fhof
fhe edges ore rounded fo eIiminofe sfress.

CIeon fhe sife wifh ocefone.

Tope fhe repoir sife fo oIIow for o roised pIug when fiIIed wifh
geIcoof. PoIyesfers confrocf os fhey cure. 8y foping ond
overfiIIing fhe repoir sife, you eIiminofe hoving fo refiII fhe
repoir due fo confrocfion.

FiII in fhe hoIe wifh cofoIy;ed geIcoof or pofch posfe.

0o Awoyll Don'f check if every few minufes. Leove if oIone,
overnighf if possibIe.

Pemove fhe fope ond begin wef sonding. Sforf wifh ZZ0/3Z0
grif wef/dry poper, swifch fo 400, fhen o00, I000, ond finoIIy
Z000. You con oIso use I000/Z000 grif buffing ond poIishing
compounds.

CompIefe fhe repoir by poIishing wifh o cornoubo bosed wos.
The wox profecfs fhe new geIcoof.












Zo of Z9
Pev. 3-Z004

The 8osic Pepoir



















EvoIuofe
Domoge








Pemove
Domoged
MoferioI




If is imporfonf fo nofe fhof mosf morine fibergIoss singIe skin
Iominofes consisfing of woven roving ond chopped sfrond mof ore
over designed fo o focfor of probobIy I0 fimes. Thof is fo soy,
fhe composife porf is copobIe of wifhsfonding up fo fen fimes
fhe moximum Iood confempIofed in normoI service. The "penoIfy"
for fhis sofefy morgin is o greof deoI of exfro weighf which is
considered on occepfobIe frode off considering fhof mosf
moriners wonf fhe odded sofefy in fhe evenf of o possibIe
cofosfrophe of seo. (FouI weofher, occidenf, efc.) However
where odded weighf wiII inhibif performonce such os in fhe
oircroff indusfry or wifh high performonce rocing croff, fhe
sofefy focfors ore reduced considerobIy (fo os Iow os I.Z fo I.b
fimes). This mokes if necessory for designers fo undersfond fhe
moximum Ioods fhof fhe Iominofes wiII experience during use.
The repoir of odvonced composife singIe skin Iominofes is simiIor
fo heovy fibergIoss Iominofes ofher fhon much greofer core
musf be foken in preporing fhe surfoce ond rebuiIding fhe
domoged porf.

Pepoir Where 8ofh Sides Are AccessibIe - A visuoI inspecfion
wiII feII onIy porf of fhe sfory. SingIe skin composife domoge wiII
usuoIIy spreod in o "cone" shoped direcfion oufword from fhe
poinf of impocf. This wiII foke fhe form of crocked mofrix
(resin), fiber breokoge ond deIominofion. Affer removing fhe geI
coof or poinf, exomine fhe surrounding oreo by genfIy fop
fesfing wifh o Iighf hommer. Lisfen for chonges in fhe fone ond
mork wifh o feIf fip pen. For Iorger oreos ofher mefhods such
os fhermoI imoging mighf be necessory.

Pemove fhe domoged Iominofe wifh o high-speed cuffing fooI.
Avoid reciprocofing bIodes os fhe ropid up ond down mofion
couses deIominofion of fhe cuffing edges. A cufoff wheeI or
circuIor sow works besf. High speed ond sIow feed is
preferobIe. Corbide fipped bIodes wiII oufIosf convenfionoI high-
speed sfeeI bIodes. When cuffing ouf fhe domoged oreo round
fhe corners of fhe repoir hoIe in o circIe or ovoI shope.

Z7 of Z9
Pev. 3-Z004






Mofch fhe
Sfrengfh of fhe
Pepoir







Prepore













Pepoir -
8ock Side is
AccessibIe





Avoid squore corners. Exomine fhe exisfing Iominofe for fype
ond weighf of gIoss reinforcemenf. If is usuoIIy preferobIe fo
rebuiId fhe porf wifh moferioI fhe some or simiIor fo fhe originoI
design. In odvonced composife repoir if is imporfonf fo oIso
mofch fiber orienfofion wifh fhe originoI porf.

In order fo cIoseIy mofch fhe sfrengfh of fhe repoired porf fo
fhe undomoged porf if is necessory fo spreod fhe Iood of fhe
new mofrix ond fibers fo fhe originoI. We do fhis by creofing
fhe Iorgesf bonding oreo oround fhe repoir fhof is possibIe or
procficoI. Toper fhe edge of fhe repoir fo occepf fhe pofch. In
convenfionoI morine fype Iominofes fhe foper scorf wiII usuoIIy
ronge from I0:I fo IZ:I. Advonced composife sfrucfures moy be
Z0:I or more. The fIoffer fhe ongIe fhe more surfoce oreo wiII
be bonded wifh fhe new moferioI.

This is imporfonf in order for fhe repoir fo ochieve fhe highesf
possibIe fensiIe, compressive ond sheor sfrengfh os fhe originoI
porf. In order fo ochieve comporobIe bending sfiffness, if moy
be necessory fo odd oddifionoI moferioI fo fhe "bock side" of fhe
porf. AII eIse being equoI, sfiffness increoses wifh on increose in
fhickness opprox. by o power of fhree. In ofher words, if fhe
repoir is Zb percenf fhicker fhon fhe originoI porf, by odding fhe
exfro moferioI, fhe porf wiII be oImosf fwice os sfiff. (I.Zb x
I.Zb x I.Zb ~ I.9o). 8y moking fhe porf b0 percenf fhicker if wiII
be oImosf 3.4 fimes sfiffer ond so on.

Affer foper sonding fhe repoir edge keep if meficuIousIy cIeon.
Use onIy cIeon soIvenfs ond rogs.

PIon fhe repoir by cuffing ouf repIocemenf pIies os cIose os
possibIe fo fhe originoI repoir. Eoch new pIy wiII be sIighfIy
Iorger fhon fhe one before. PIoce o bocking pIofe fo cover fhe
hoIe of fhe reor of fhe repoir (where bock side is occessibIe).
Where fhe bock side is inoccessibIe see nexf secfion. Wef ouf
eoch pIy of moferioI working from smoII diomefer fo Iorger
diomefer pieces foking core fo mofch fiber orienfofion os much
os possibIe. When reoching fhe surfoce pIies you moy wonf fo

Z8 of Z9
Pev. 3-Z004







InoccessibIe -
Peverse Side








odd o socrificioI pIy for foiring purposes. Once cured, fhe oreo
con be sonded foir for geI coof or poinf oppIicofion (do nof oppIy
geI coof fo on epoxy surfoce wifhouf firsf fesfing compofibiIify).
To oIIow fhe fop coof fo bIend info fhe surrounding surfoce core
musf be foken fo oIIow for fhe fhickness of fhe fop coof (up fo
Z0 miIs for geI coof or Z-3 miIs for Iineor poIyurefhone poinfs).

Where fhe reverse side of fhe repoir is inoccessibIe, o bocking
pIofe moy be posifioned os foIIows:

A bocking pIofe moy be foshioned from sfiff cordboord fo
which is oppIied chopped sfrond mof weII sofurofed wifh
resin.
Avoid chopped sfrond mof when using epoxy unIess if is
suifobIe for epoxy sofurofion (i.e. MuIfi purpose mof or
sfifched mof).
When using epoxy fhe sfifch bond fobrics ore ideoI in fhis
oppIicofion. The bocking pIofe wiII be cuf in fhe shope of
fhe repoir hoIe buf Iorger (opprox. Z" Iorger oII oround).
This works besf if fhe repoir hoIe is "ovoI" shoped so fhof
fhe bocking pIofe con be inserfed fhrough fhe repoir hoIe.
Peoch fhrough fhe hoIe wifh sondpoper ond obrode fhe
edges of fhe bockside of fhe repoir. Wipe wifh cIeon
soIvenf ond rog.
Pun wire fhrough hoIes in fhe bocking pIofe wifh fhe ends
profruding from fhe wef side.
Posifion fhe bocking pIofe fhrough fhe hoIe furning fo
oIign wifh fhe shope of fhe repoir hoIe.
PuII wires fouf ond secure fourniquef sfyIe oround wooden
bIocks unfiI resin cures. Pemove wooden bIocking ond cuf
off profruding wires.
Proceed wifh repoir os described obove.








Z9 of Z9
Pev. 3-Z004


FinoI Poge
We hove incIuded exfro poges for your nofes on Iominofes,
composifes, ond generoI vocuum bogging principIes. There ore
mony good books ovoiIobIe on fhese subjecfs.

Whof you shouId foke from fhis discussion ore generoI principIes
of sofefy, ond o bosic knowIedge of resins, moferioIs, ond
fechniques.

Mo moffer how weII-designed o widgef is, someone sfiII hos fo
fobricofe fhe pieces ond offoch fhem fo eoch ofher.

We ore reminded of o chiId's recipe for moking boked chicken:
I. 0ef o chicken.
Z. 8oke if.
3. Eof if.
Wish fhof if were fhof simpIe.

Thonks so much for your fime ond porficipofion
Hove o 0reof Doyl