Composite mold resurfacing with duratec® products - Hawkeye ...

Hawkeye Industries Inc.

There are two methods for applying StyroSafe Fast Cure
Laminating Resin.
•Use the first method when the dimensional tolerances of
the plug are tight.
•Use the second method when the dimensional tolerances
of the plug are not tight.

First Method―StyroSafe Laminate over-coated with
tooling putty for re-cut.

1. When cutting, cut the plug
dimensionally smaller than
full size, from ½ to ¾ inch
smaller.
2. When you finish shaping
your foam piece, clean and
blow off foam particles that
are left from sanding or
shaping.

3. Stir the StyroSafe in its container.
4. Pour the desired amount into a cup or bucket. The
amount to catalyze will depend on the temperature in
your work area and how quickly you will be able to
apply the product.
5. Catalyze at 1 to 2 percent with Cadox L-50 or
equivalent. The amount of catalyst used will affect gel
time, so once again, consider how quickly you will be
able to apply the product. Mix thoroughly.

6. Apply a thin film of
StyroSafe resin to
the foam. You will
want to work in an
area small enough so
that the StyroSafe
will not begin to gel
before you are
finished work.

7. Apply glass to the wet-out area
8. Wet out any dry spots, being careful
not to over saturate the glass.

9. Roll out the glass to
remove any bubbles.

10. Continue the process until
the resin and the glass have
been applied to the entire
service.

11. Scuff the entire plug with 60- to 80-
grit sandpaper, then apply a tooling
(machinable) compound.

12. Re-cut the plug to correct
dimensions.

13. Seal cut plug with Duratec
13. Seal cut plug with Duratec Polyester or Vinyl Ester
Sealer.
14. After sealer becomes tacky, apply Duratec Surfacing
Primer or Duratec EZ Sanding Primer.
15. Sand at 400 grit and let stand overnight. Finish
sanding with desired grit, compound and polish
with Aqua-Buff Tuff-Stuff Fast Cut Compound and
Aqua-Buff GlossMaster Polish.

OPTIONAL
16. For the ultimate gloss surface, apply Duratec Polyester
Hi-Gloss Coating or Duratec Vinyl Ester Hi-Gloss
Topcoat. This will be done before compounding and
polishing.
17. Sand at 400 grit and let stand overnight; finish
sanding with the desired grit, compound and polish
with Aqua-Buff Tuff-Stuff Fast Cut Compound and
Aqua-Buff GlossMaster Polish.

Second Method―StyroSafe Laminate over-coated
with Duratec Primers for immediate mold-making.

1. When you finish shaping
your foam piece, clean and
blow off foam particles that
are left from sanding or
shaping.

2. Stir the StyroSafe in its container.
3. Pour the desired amount into a cup or bucket. The
amount to catalyze will depend on the temperature in
your work area and how quickly you will be able to
apply the product.
4. Catalyze at 1 to 2 percent with Cadox L-50 or
equivalent. The amount of catalyst used will affect gel
time, so once again, consider how quickly you will be
able to apply the product. Mix thoroughly.

5. Apply a thin film of
StyroSafe resin to
the foam. You will
want to work in an
area small enough so
that the StyroSafe
will not begin to gel
before you are
finished work.

6. Apply glass to the wet out area
7. Wet out any dry spots, being careful not
to over saturate the glass.

8. Roll out the glass to remove
any bubbles.

9. Continue the process until
resin and glass have been
applied to the entire service.
10. If desired, you can build a
“thicker” surface by adding
more resin and glass.

11. Scuff the entire plug with 60- to 80-
grit sandpaper.

11. Apply Duratec Base Primer 120 mils,
4mm thick.

12. Sand with 80- to 180-grit sandpaper.
13. Apply Duratec Polyester Surfacing Primer or Easy
Sanding Primer.
14. Sand at 400 grit and let stand overnight. Finish sanding
with the desired grit, compound and polish with Aqua-
Buff Tuff-Stuff Fast Cut Compound and Aqua-Buff
GlossMaster Polish.

OPTIONAL
15. For the ultimate gloss surface, apply Duratec Polyester
Hi-Gloss Coating or Duratec Vinyl Ester Hi-Gloss
Topcoat. This will be done before compounding and
polishing.
16. Sand at 400 grit and let stand overnight; finish sanding
with the desired grit, compound and polish with Aqua-
Buff Tuff-Stuff Fast Cut Compound and Aqua-Buff
GlossMaster Polish.

• To purchase StyroSafe,
Duratec and Aqua-Buff
products contact Hawkeye
Industries toll free at 1-800-
977-0060.
• For more information about
the full line of our products,
visit our web site at
www.duratec1.com.