(b) Metal Spraying of Plastic Coating 1) Metal spray a 0.055 +0.005 inch buildup of Metco SF aluminum over plastic
casting to obtain a metal positive of surface texture.
2) Carefully remove metal sprayed positive from plastic casting.
3) Trim rough edges if present.
(c) Embossing Textures onto Mylar Film 1) Place double layer of Osnaburg cloth on surface of lower platen of a hydraulic press. 2) Place metal sprayed positive, textured side up, on Osnaburg cloth. 3) Place single sheet of mylar film, 0.001 inch x metal sprayed positive dimension,
on metal positive. 4) Place sheet of silicone rubber, 0.125 inch x platen dimension, dusted with talcum powder, over mylar film. 5) Place sheet of stainless steel, 0.040 to 0.050 inch x platen dimension, over rubber sheet. 6) Close platens of press and apply pressure of 225 psi (to total embossing area) at a temperature of 375 +10°F for 8 minutes.
NOTE: Excessive heating will cause mylar film to break down and discolor. This will cause mylar film to adhere to Epibond 126 when making repairs.
7) Mylar film shall be cooled to temperature of 100 +10°F before pressure is released.
8) Before removing mylar film from embossing plate, make a spiral line on top side of mylar from center to edges, using felt-point marking pen. Spiral lines shall be kept approximately 1/2 inch apart. Purpose of marking is to provide identification of negative side of film no matter how or where it is cut.
(d) Definitions of negative and positive surface textures. To clarify use of terms negative and positive surface textures, following definitions are offered: 1) Texture on decorative material - positive 2) Texture on plastic splash casting - positive 3) Texture on metal sprayed plate - positive 4) Texture on unmarked surface of embossed mylar - negative 5) Texture on sweep-fair patch (Epibond 126) - positive
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(e) Repair Procedures 1) Trim ragged edges of damaged material with No. 1 X-Acto knife and No. 11 blade. 2) Clean material to be repaired as described in material section (Fig. 201). 3) Apply film of heavy duty traffic wax from edge of damaged area outward. Wax
shall be applied at least 2 inches in all directions from edge of damage.
NOTE: Care should be exercised to keep wax out of area to be repaired.
4) Accurately weigh and thoroughly mix the following materials: 10.0 parts by weight -Epibond 126 resin; 6.5 parts by weight - HN 9812 Hardener; 1.5 parts by weight - Ferro No. 7005 white titanium dioxide pigment; 16.0 parts by weight - calcium carbonate.
5) Apply sufficient resin to fill damaged area.
6) Cut a piece of embossed mylar 1/4 inch larger than periphery of damaged area and place over resin. Unmarked or negative side of mylar should be against resin.
7) Lubricate upper surface of mylar film with light machine oil.
8) Working from center of repair sweep and fair resin to desired contour using 1/16 x 3 x 4 inch rigid squeegee.
NOTE: It is very important that as much as possible of excess resin be swept out from under mylar film.
9) Allow resin to cure for eight hours at 700F or two hours at 1200F.
10) After cure, strip mylar film from resin.
11) Using stiff bristle brush which has been dipped in aliphatic naphtha (TT-N-95A),
remove excess resin and wax from area surrounding repair.
NOTE: Any excess resin left in area surrounding damage will show up when repair is painted.
WARNING: RESIN IS FLAMMABLE AND MAY AFFECT EYES, SKIN, AND RESPIRATORY TRACT. USE IN A WELL VENTILATED AREA. AVOID PROLONGED BREATHING OF VAPORS. AVOID EYE AND REPEATED SKIN CONTACT. KEEP AWAY FROM SPARKS AND FLAMES. CHEMICAL GLOVES AND GOGGLES WILL BE WORN. RESPIRATOR IS REQUIRED UNLESS WAIVED BY THE BIOENVIRONMENTAL ENGINEER.
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G. Repair Method No. 6
(1)
General:
(a) This method is used to repair cuts or tears which completely penetrate decorative material. Size of patch required shall be determined by extent and type of damage.
(2)
Equipment and Materials
(a)
Patch Material
(b)
Tape (Permacel No. 94)
(c)
X-Acto Knife - No. 1 and X-Acto Blade No. 11
(d)
Adhesive, Eastman 910
(3)
Repair: (patching)
(a)
Patch material shall be selected from scrap materials. Patch material to be used shall match damaged area as closely as possible in shade of color, design, and surface texture. Correct matching may be accomplished by holding various pieces of scrap material over damaged area and observing color, design, and texture compatability.
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