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Date: Wed, 04 Apr 2012 16:08:27 -0400
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From: "Tom Wallace" <tlwcfii@yahoo.com>
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Subject: RE: Window Bonding
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Thank you to all that have responded on this subject and the assistance I
have received in solving this issue.

In Summary I have found that the Hysol 9360 bond to the Acryic window is
inadequate IMHO.   I have devised a method to use Hysol 9360 bonded to the
fuselage in the Window bond area and then use WeldOn45 to bond the acrylic
window to the Hysol.  I have a detailed document that describes the test I
performed on the bonds before selecting this method and the process I used
to install the windows.

I don't profess to be an "expert" builder but would be more than happy to
share my findings with anyone that is interested.  George Mesiarik of LP
Aero Plastics, Inc. was very helpful in providing information that led me to
this process.

Please e mail me directly if you are interested in the details and I will
send you the document mentioned above.

Blue Skies,

Tom

-----Original Message-----
From: Tom [mailto:Tom@wellswoodturning.com] 
Sent: Sunday, November 20, 2011 9:48 AM
To: lml@lancaironline.net
Subject: Window Bonding

I installed two windows in my ES with Hysol 9394. I followed the
instructions explicitly and after cure (14 days)there were no air gaps or
voids in the bond area. As I was removing the clamps after cure that held
the window in place I noticed small areas near where I pushed on the
fasteners debonded. By pushing on the fiberglass around the window from the
inside I could see the Hysol debond from the plexi glass. I ended up
removing both windows by debonding them using this method.

I had been using Hysol 9394 as that at one point in time was the Hysol being
sold by Lancair. After reviewing the spec sheets of Hysol 9360 vs 9394 the
major difference noted was the peel strength of the 9394 (5 Lb/in) vs the
9360
(50 Lb/in) per the data sheets. I did a crude test using 9394 and 9360
bonding a piece of prexiglass to a piece of fiberglass and allowing it to
cure for
14
days. I found that the plexiglass could be removed from both simply by
flexing the fiberglass although the 9360 seemed to be slightly better bond.
So...before
I bond these windows in again I would like to be sure of what to use. Has
anyone else experienced this phenomenon?

The supplier of the Lancair windows uses MIL-S-8802 to bond windows to
aluminum and indicated they thought some builders had used it to bond
windows to fiberglass. They also indicated they used Weld-on 40 to bond
fiberglass to the edge of the windows with good results.

Any insight on this would be greatly appreciated.

Blue Skies,

Tom