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Products— Duratec Vinyl Ester Mold Repair Putty (1804-007 Untinted, 1802-007 Black, 1808-007 Orange, 1814-007 White) Duratec Polyester Surface Primer (702-003 Black, 707-002 Grey, 707-082 Light Grey, 714-002 White) Duratec Vinyl Ester Primer (1799-006 Grey, 1702-006 Black, 1794-006 White) Duratec Polyester High Gloss Coating (904-040 Clear, 602-021 Black) Duratec Vinyl Ester Hi-Gloss Topcoat (1902-045, 1904-045 Clear/Untinted, 1908-045 Orange) Duratec Thinner (39LAC-3) Duratec Pot Life Extender (39GELX)

Resurfacing a structurally sound mold is a fast and inexpensive way to get more value out of the original investment. Resurfacing eliminates mold marks on parts, and allows the mold to recover the original shine and gloss.

Application Conditions

The mold surface must be stripped with a chemical cleaner, and sanded with 40 grit sandpaper. After sanding, wipe down the mold with a rag soaked with acetone to remove dust. Allow to fully dry before moving on.

The shop, air and mold must be above 60° F for the Polyester Duratec products, and above 68° for the Vinyl Ester Duratec products.

Repair cracks, chips, gouges in the tooling gelcoat if necessary. (See Mold Repair Prep Module at back for more guidance.)

Application Instructions – Duratec Mold Repair Putty (1802-007, 1804-007, 1808-007)

1. Apply two layers of masking tape around the area that will be repaired. This allows the putty knife to reference a higher surface that will allow for shrink and sanding without creating a low area.

2. To ensure proper adhesion, rub the catalyzed putty into the repair area and follow by applying with a spatula, putty knife or squeegee. Fill the void completely by working the putty in all directions. For deep repairs (more than gelcoat thickness), repeat the process to assure a porosity-free surface. If the Duratec Mold Repair putty is still tacky it is not necessary to sand between applications. If the surface is tack-free, sand with 80 grit between applications.

3. Leave the surface slightly mounded to allow for shrinkage as the putty cures. 4. Use a heat gun or infrared lights to heat the Mold Repair Putty, and assure full cure. 5. When cured (20-30 minutes, sand the cured putty until it is even with the surface of the

surrounding tooling gelcoat. See Modules at the back for further guidance on stir directions, catalyst, spray guns, pot life extender & thinner.

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Application Instructions – Duratec Primer

Using a Duratec Primer on the prepared mold surface: Duratec primers are designed to have great adhesion, and to resist fish-eyes and other application defects. Choice: For molds that will see temperatures below 170° F we recommend Duratec Surface Primer. For molds that will see higher temperatures, we recommend Duratec Vinyl Ester Primer.

1. Shake and thoroughly stir the primer. 2. Catalyze with 2% of standard MEKP Catalyst. Mix thoroughly. 3. Spray Duratec primer. 4. Sand with 180 or 220 grit paper. Take care to remove a consistent amount of Duratec Primer.

Sand only enough to remove any orange peel and to abrade the surface. Allow the mold to stand for at least eight hours before proceeding.

Choice: The Duratec VE Primer can be sanded with fine grits, and polished up to a gloss approaching 85%. This may be enough for molds that make parts that are later painted, or where a dull appearance is accepted. For brighter molds with better shine, topcoat with Duratec Vinyl Ester Hi-Gloss Topcoat.

For a Class A finish resurface with Duratec Vinyl Ester Hi-Gloss Topcoat:

Application Instructions – Duratec Topcoat

1. Assure the work area is clean and free of dust. Make sure that no one is grinding and sanding near the mold.

2. Shake or stir the VE Topcoat. Pour the VE Topcoat through a filter before use. 3. Note: the Duratec Pot Life Extender does not work with the VE Topcoat. 4. Wipe down the primed and sanded mold with a rag soaked with acetone. Do not use a tack rag. Thinner Recommendations: 5. It is not usually necessary to use a thinner with the VE Topcoat. 6. Catalyze Topcoat. Add 2% low hydrogen peroxide MEKP Catalyst. 7. Apply the Duratec Vinyl Ester Topcoat, build a 12-25 mil film. Application recommendations for

the Duratec Vinyl Ester Topcoat: 8. Make the first spray pass a “dust coat” that does not completely cover the surface. It is ideal to

have the surface covered with fine droplets of Duratec Vinyl Ester Topcoat, looking like dust on the primer. This prevents fish-eyes and surface crawl.

a. Wait 2 minutes, and apply a build coat of the Duratec VE Topcoat. Wait 2 minutes, and apply another coat in the opposite direction. The VE Topcoat should be about 5 mils thick at this point.

b. Wait 15 minutes, apply another 5 mils. c. Wait 15 minutes, apply another 5 mils.

i. Note: thicker application allows for more aggressive sanding and polishing once the VE Topcoat has cured. A thinner application allows the mold to stay true to the original dimensions. Apply a minimum of 12 wet mils to assure at least 10 dry mils of VE Topcoat.

d. Apply up to 25 wet mils, and allow to fully cure.

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9. For full cure, sand the Duratec VE Topcoat after it is cured. Sanding and polishing is necessary to achieve full cure and avoid mold sticking.

10. Once the Duratec Vinyl Ester Hi-Gloss Topcoat has cured completely; open the surface with sandpaper. The grit should be chosen to flatten out any surface profile, but avoid deep sanding scratches in the surface. Proceed from 400, 600, 800 and 1000 grit paper. Wet sanding helps but is not required.

11. Compound and Polish with Aqua Buff 1000 and 2000 The mold is ready to for release, and to go back into service.

See Modules at the back for further guidance on stir directions, catalyst, spray guns, pot life extender, thinner, buffing, and coating.

SAFETY PRECAUTIONS: Check the material safety data sheet for recommendations on protective equipment. The Duratec products are extremely flammable.

Liability/warranty statement: Our products are intended for sale to industrial and commercial customers. We request that customers inspect and test our products before use and satisfy themselves as to contents and suitability. Nothing herein shall constitute a warranty, expressed or implied, including any warrant of merchantability or fitness, nor is protection from any law or patent to be inferred. All patent rights are to be reserved. The exclusive remedy for all proven claims is replacement of our materials and in no event shall we be liable for special, incidental or consequential damages. Duratec is a registered trademark of Dura Technologies. Aqua Buff is a registered trademark of Hawkeye Industries.

REVISED 3-5-15