This article explains how to use epoxy resin from West System. Epoxy resin can be used as an adhesive, clear coat or for laminating fiberglass.
By Jim Hingst @hingst_jim
In the sign industry one of the most widely used epoxy resins is the West System Epoxy. Because of its versatility and durability, old school sign makers frequently select this product for projects.
West System 105 epoxy resin is the key component in a variety of epoxy formulations including coatings, lamination and adhesives. |
The West System is comprised of three components: the 105 epoxy resin, a
hardener and a filler. Depending on which hardener and filler you select, you
can use it to as an adhesive, or as a clear coat or for laminating fiberglass
or to repair damage to a surface.
Mixing Epoxy Resin
What’s important when working with any epoxy system is that the
resin and the hardener are mixed in the correct proportions. If you happen to
mess up the mixture ratios, the resin will not cure and you will end up with a
mess on your hands.
Metering out the right proportions is not difficult if you use the
West System 300 mini pumps. All you need to remember is to combine one full
pump of resin with one full pump of hardener.
After dispensing the two components in a clean container, you must
thoroughly mix the resin and hardener together. Whenever you mix any components,
make sure that you scrape the sides and the corner at the bottom of the
container.
Epoxy is exothermic. After the resin and hardener are mixed a
chemical reaction occurs. As the mixture cures, the epoxy gets hot. CAUTION: Larger batches can get really hot really fast.
Difference Between Epoxy Resin and Polyester Resin
NOTE: Epoxy resin and polyester resin are not
the same thing. Polyester resin tends to be much stiffer. Another difference is
cost. Polyester resin is much cheaper. Epoxy resin, on the other hand, is more flexible
and stronger. For extremely demanding applications, a two part, marine grade
epoxy resin, such as the West System product, is usually a much better choice
than polyester resin. These glues form a very strong bond and stick to just
about anything. That can be a big advantage if you are bonding two different
types of materials, such as wood and metal or wood and plastic.
Test,
Don’t Guess. As a word of caution, if you are bonding two different types of
materials it is best to test the bond strength of the dissimilar materials
prior to fabrication. While epoxy glues stick to just about anything, there are
some low energy plastics, such as polyethylene, that it will not stick to.
Epoxy Resin Hardeners
West System offers many different types of hardeners. The major
difference from one harder to another is the rate of speed at which the mixture
cures. The 205 hardener, which is very popular, sets up fast. In warm weather
environments, you may need a slower setting product, such as the 206 hardener
or the 209 hardener. The 207 hardener is a specialty super clear hardener,
which you can use in a variety of applications, such as adhesives, surface repairs, fiberglass lamination as well as as a coating.
Epoxy Resin Fillers
The third component is the filler. You must select the right filler
for the application. The 405 filler is great for general purpose adhesive
applications. Gradually add thickener to the resin/hardener mixture until you
attain the desired consistency. For adhesive applications the epoxy should have
the consistency of creamy peanut butter.
The high density fillers, such as West System’s 405 or 406, change
the structural characteristics of the epoxy, making it either stronger or
thicker. These high density fillers become very hard after the epoxy cures,
which makes sanding difficult.
By comparison low density fillers, such as West System’s 407, are
designed for filling holes or to add mass to a surface which can be easily
shaped in a manner that Bondo is used
for cosmetic purposes. Lighter weight filler are much easier to sand.
Working with Epoxy Glues
Working with epoxy glues
requires a slight change in your fabrication process. Ratios of resin and
hardener will vary from one manufacturer to another. Be sure to read the
manufacturer’s technical bulletins prior to use. Follow the instructions to the
letter. Failure to mix the resin and hardener in the correct proportions can
result in product failure.
If you are bonding pieces together with an epoxy, you must clamp the parts while the adhesive is still in its liquid state. Once the epoxy reaches the rubber-like gel state it is no longer workable.
When edge clamping boards,
you just need to snug them together with just enough pressure to hold parts
together. Any additional pressure can
squeeze out too much glue and actually weaken the bond. You can clean any glue
that squeezes between the boards with a
putty knife and wiping the surface with denatured alcohol. Cleaning up the glue
when it is soft is preferable to having to sand hardened glue.
Until the gel finally solidifies, you can coat the surface with additional epoxy. Even after the epoxy hardens to the point that you can no longer dent the surface with your fingernail, it can take as much as a week for the resin to completely cure.
The open time that you have to work with the epoxy will depend
several factors, including the size of the batch that you are mixing and the ambient
temperature of your shop. As a rule of thumb, the larger the batch size, the
more heat is generated and the faster the epoxy cures. For this reason, it is
often better to mix several smaller batches than one big batch.
Epoxy also cures faster as the ambient temperature increases. The
optimal temperature is 70°F. For hot weather applications, use a slower
hardener. Do not use epoxy when the temperatures of your shop or the materials
are below 50°F. Low temperatures can compromise adhesion.
Safely Working with Epoxy Resins
Epoxies are great for bonding many different types of materials,
such as wood, metals and plastics. To ensure good adhesion, you must prep the
surface, just as you would prep a surface for vinyl application. For optimal
results, follow the manufacturer’s surface prep recommendations. When using
epoxies, you should also follow the maker’s recommendations regarding safe
handling, storage and disposal. Here are
some general safety rules that you should follow in your shop:
- Work in a well-ventilated area.
- Use appropriate personal safety equipment including safety glasses, heavy-duty gloves, and an air respirator with a chemical cartridge.
- When sanding cured epoxy, wear a dust mask or air respirator.
- After working with epoxy, thoroughly wash your hands with soap and water.
- Never use a solvent to clean epoxy from your hands.
- Dispose of materials responsibly, in accordance with governmental regulations. You can discard unused epoxy after the mixture has cooled down.
- Generally the shelf life for resin and hardener is about two years. Store these components in a cool, dry place away from sunlight. Storage in a warm environment shortens the shelf life.
Conclusion
For demanding applications,
epoxy resin is a great choice. These products are waterproof, solvent resistant and chemical
resistant. With respect to service temperature range, epoxy resins withstand
extreme heat and cold, which make them great for outdoor applications.
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Wet Applications. Dry applications are typically recommended for most vinyl applications. For those exceptions to the rule, this instructional video explains the right way to perform a wet application. Click to Link
Application of Window Graphics. Installing vinyl graphics on glass can be challenging, because the adhesive aggressively grabs onto this high energy surface. Repositioning graphics on window is generally difficult, if not impossible. This instructional video explains how to dry apply window graphics right the first time. It also describes the necessary steps required for surface preparation. Click to Link
Transferring Frosted Window Graphics Films. Because frosted window films are highly textured, transferring cut vinyl graphics can be problematic. This video provides direction in selection of the right application tape and how to apply these films quickly, easily and without problems. Click to Link
3-Step Surface Prep. This instructional video describes how to properly clean the surface of a vehicle before applying pressure sensitive vinyl graphics to a trailer or doing a full wrap of a car or van. This three step surface prep involves detergent washing, solvent cleaning and a final wipe down with IPA. Click to Link
Vinyl Application Over Rivets. Applying vinyl graphics on vehicle surfaces with rivets is challenging for most sign makers. Vinyl failures to these surfaces are all too common. This video demonstrates some tips and procedures, used by professional decal installers, which will make these demanding applications easier and more trouble-free. Click to Link
Vinyl Application to Corrugations. Learn how to apply vinyl graphics to corrugations in a relaxed state. Forcing films into the valleys of corrugations puts too much mechanical stress on the film. Sooner or later, the vinyl will lift or tent in valleys. Click to Link
Applying Air Egress Vinyls. Vinyl films with air egress release liners have almost eliminated bubbles and wrinkles from applied graphics. Air egress release liners with their highly textured surface structure are problematic. Not much will stick to these liners other than the vinyl film. At RTape our best premask solution for air egress liners is a special Conform® tape called 4761RLA. Click to Link
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CLICK HERE FOR HINGST SIGN POST ARTICLES IN PDF FORMAT
Vinyl Application Videos
Squeegee Technique. Nothing is more basic in vinyl application than the squeegee. But some squeegees work better than others. And there are right ways and wrong ways to use this simple tool. This video clip reviews squeegee selection, squeegee care and squeegee technique. Click to Link
Wet Applications. Dry applications are typically recommended for most vinyl applications. For those exceptions to the rule, this instructional video explains the right way to perform a wet application. Click to Link
Application of Window Graphics. Installing vinyl graphics on glass can be challenging, because the adhesive aggressively grabs onto this high energy surface. Repositioning graphics on window is generally difficult, if not impossible. This instructional video explains how to dry apply window graphics right the first time. It also describes the necessary steps required for surface preparation. Click to Link
Transferring Frosted Window Graphics Films. Because frosted window films are highly textured, transferring cut vinyl graphics can be problematic. This video provides direction in selection of the right application tape and how to apply these films quickly, easily and without problems. Click to Link
3-Step Surface Prep. This instructional video describes how to properly clean the surface of a vehicle before applying pressure sensitive vinyl graphics to a trailer or doing a full wrap of a car or van. This three step surface prep involves detergent washing, solvent cleaning and a final wipe down with IPA. Click to Link
Vinyl Application Over Rivets. Applying vinyl graphics on vehicle surfaces with rivets is challenging for most sign makers. Vinyl failures to these surfaces are all too common. This video demonstrates some tips and procedures, used by professional decal installers, which will make these demanding applications easier and more trouble-free. Click to Link
Vinyl Application to Corrugations. Learn how to apply vinyl graphics to corrugations in a relaxed state. Forcing films into the valleys of corrugations puts too much mechanical stress on the film. Sooner or later, the vinyl will lift or tent in valleys. Click to Link
Applying Air Egress Vinyls. Vinyl films with air egress release liners have almost eliminated bubbles and wrinkles from applied graphics. Air egress release liners with their highly textured surface structure are problematic. Not much will stick to these liners other than the vinyl film. At RTape our best premask solution for air egress liners is a special Conform® tape called 4761RLA. Click to Link
About Jim Hingst: After fourteen years as Business Development Manager at RTape, Jim Hingst retired. He was involved in many facets of the company’s business, including marketing, sales, product development and technical service.
Hingst began his career 42 years ago in the graphic arts field creating and producing advertising and promotional materials for a large test equipment manufacturer. Working for offset printers, large format screen printers, vinyl film manufacturers, and application tape companies, his experience included estimating, production planning, purchasing and production art, as well as sales and marketing. In his capacity as a salesman, Hingst was recognized with numerous sales achievement awards.
Drawing on his experience in production and as graphics installation subcontractor, Hingst provided the industry with practical advice, publishing more than 150 articles for publications, such as Signs Canada, SignCraft, Signs of the Times, Screen Printing, Sign and Digital Graphics and Sign Builder Illustrated. He also posted more than 325 stories on his blog (hingstssignpost.blogspot.com). In 2007 Hingst’s book, Vinyl Sign Techniques, was published. Vinyl Sign Techniques is available at sign supply distributors and at Amazon.
© 2016 Jim Hingst
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