X-Virus-Scanned: clean according to Sophos on Logan.com Return-Path: Received: from nskntmtas01p.mx.bigpond.com ([61.9.168.137] verified) by logan.com (CommuniGate Pro SMTP 6.0.5) with ESMTP id 6418699 for lml@lancaironline.net; Wed, 14 Aug 2013 21:09:16 -0400 Received-SPF: pass receiver=logan.com; client-ip=61.9.168.137; envelope-from=frederickmoreno@bigpond.com Received: from nskntcmgw08p ([61.9.169.168]) by nskntmtas01p.mx.bigpond.com with ESMTP id <20130815010839.EUWK21423.nskntmtas01p.mx.bigpond.com@nskntcmgw08p> for ; Thu, 15 Aug 2013 01:08:39 +0000 Received: from Razzle ([1.122.172.78]) by nskntcmgw08p with BigPond Outbound id Cp8d1m00J1hqmBD01p8evf; Thu, 15 Aug 2013 01:08:39 +0000 X-Authentication-Info: Submitted using ID frederick.moreno@bigpond.com X-Authority-Analysis: v=2.0 cv=MrvQGhme c=1 sm=1 a=Yw52ToOdFr1VE5+1veiJuw==:17 a=JDadKst33uMA:10 a=IkcTkHD0fZMA:10 a=1IlZJK9HAAAA:8 a=jp95Rsh2JikA:10 a=Ia-xEzejAAAA:8 a=005pP79xprLJTAOkdLMA:9 a=QEXdDO2ut3YA:10 a=EzXvWhQp4_cA:10 a=YrR7H3wz4uF1R9wz:21 a=G1gn4vudN0CSPMqZ:21 a=pGLkceISAAAA:8 a=93UZuU0ITFCBiXsvnxoA:9 a=_W_S_7VecoQA:10 a=MSl-tDqOz04A:10 a=6g9-IUC6vOhYoYyp:21 a=xV3igvsA2NbZaa-h:21 a=nSVHc8sMicHbI9na:21 a=x0mLEhdcI6ghJkqIEpcA:9 a=HXjIzolwW10A:10 a=dvIeMUh3dxkolpdY:18 a=Yw52ToOdFr1VE5+1veiJuw==:117 MIME-Version: 1.0 Message-Id: <520C2A71.00005C.02780@RAZZLE> Date: Thu, 15 Aug 2013 09:10:09 +0800 Content-Type: Multipart/related; charset="utf-8"; type="multipart/alternative"; boundary="------------Boundary-00=_XKSJ3EL5BHK000000000" X-Mailer: IncrediMail (6395274) From: "Frederick Moreno" X-FID: FLAVOR00-NONE-0000-0000-000000000000 X-Priority: 3 To: "Lancair Mail (lml@lancaironline.net)" Subject: Fw: Wing closing epoxy --------------Boundary-00=_XKSJ3EL5BHK000000000 Content-Type: Multipart/Alternative; boundary="------------Boundary-00=_XKSJYPP66RO000000000" --------------Boundary-00=_XKSJYPP66RO000000000 Content-Type: Text/Plain; charset="utf-8" Content-Transfer-Encoding: quoted-printable Hi Mike: =0D =0D The bond areas on the wing skins is so huge that the safety factors for strength are massive. We calculated that the bond area for the wing spare= to skin alone is enough to lift a 747 using the quoted values for the earlie= r Hysol. The key is resistance to avgas which all of them have. I would = use the stuff in your fridge and be confident. =0D =0D One hint for bonding skins. Drill lots of witness holes (1/8 in diameter works fine) over the spars. If you put a smaller drill drill or stiff wir= e down the holes when you bond the wing, you will know how thick the layer = of epoxy is under the skin and on top of the spar. I found that it was MUCH thicker than expected (I planned for 0.020 inch when calculating quantity= ), and so had to pile a lot of weight on the wing to get the squeeze out and proper wing shape. A source of vibration would help. =0D =0D As it was, I had lots of lead bags and 5 gallon buckets filled with rocks for both wings, and used them all on one wing to get the stuff to squeez= e out and get the proper wing shape. Saddles were pulled down tight, but b= ent ALL the rocks in buckets were piled on top of the lead bags in between = the wing saddles of the first wing to get everything to settle into place. T= he second wing skin had to wait for another day. =0D =0D As I recall, we used a crew of four or five to mix epoxy, apply, put dow= n the skin, and then lock it in place and them pile up buckets. I would ha= ve more were I to do it again, with a good briefing at the start. =0D =0D My guess was that we had over 500 pounds of weight to squeeze out the epoxy/flox mix. Temperature makes a huge difference in viscosity and squeeze out. You want cool to prevent the stuff cooking off too soon, bu= t warm to make it thin. Speed is important and having lots of spreading tools and hands is mandatory.=0D =0D Post inspection looking through the holes Into tanks and with mirrors int= o the fuel fill port, we found a nice squeeze out, but no drips of excess, = so the estimate of 0.020 inch thickness for the bond line worked out OK. =0D =0D Fred Moreno=0D =0D =0D =0D =0D -------Original Message-------=0D =0D From: Mike Baudhuin=0D Date: 14/08/2013 7:51:51 PM=0D To: lml@lancaironline.net=0D Subject: Wing closing epoxy=0D =0D I am preparing to close a set of wings and have some questions about Hyso= l epoxy. I've reviewed previous posts and there hasn't been much said for awhile, perhaps because wings are coming from factory closed now.=0D =0D =0D I went to Aircraft Spruce and said "I need six quarts of Hysol." They so= ld me six quarts of Hysol. I used it to epoxy in a fuel drain and probe and was asked by Matthew Colliers why it wasn't blue. So, I looked closer at= my manuals and saw that it calls for epoxy and flox if temperatures are belo= w 70 degrees and Hysol 9339 if temperatures are above 70 degrees. I then w= ent to the Lancair website and found they don't even carry Hysol 9339, but ha= ve changed to Hysol 9360. The product Aircraft Spruce sells is Hysol 9430.=20 Lancair tech support says they don't know why 9360 is specified. "That w= as selected by the guy before me."=0D =0D =0D Aircraft Spruce says - =0D =0D "This new and improved Hysol glue replaces the old EA-9410-2 glue. EA-943= 0 has the same characteristics as the EA-9410, but has a 50 minute pot life instead of the 30 minute pot life of the EA-9410 at 77=C2=B0F. Used exten= sively in the Strojnik S2A sailplane and many other homebuilts."=0D =0D Locktite tech support and the data sheets show the pot life, tensile and shear strenght to be almost identical. The one difference I can find is that the 9360 specifies shear at different temperatures while 9430 specif= ies the shear strenght only at 77 degrees. The guy from Locktite couldn't explain the differences, and said "they appear to be very similar product= s". Can anyone tell me what makes the 9360 product better suited for Lancair wings? Is there a reason not to use the six quarts of 9430 in my fridge?= =0D =0D =0D Mike Baudhuin=0D =20 --------------Boundary-00=_XKSJYPP66RO000000000 Content-Type: Text/HTML; charset="utf-8" Content-Transfer-Encoding: quoted-printable
Hi Mike:
 
The bond areas on the wing skins is so huge that the safety fac= tors for strength are massive. We calculated that the bond area for = the wing spare to skin alone is enough to lift a 747 using the quoted val= ues for the earlier Hysol.  The key is resistance to avgas which all= of them have.   I would use the stuff in your fridge and be confide= nt.
 
One hint for bonding skins.  Drill lots of witness holes (1/8 i= n diameter works fine) over the spars. If you put a smaller drill dr= ill or stiff wire down the holes when you bond the wing, you will know ho= w thick the layer of epoxy is under the skin and on top of the spar. = ; I found that it was MUCH thicker than expected (I planned for 0.020 inc= h when calculating quantity), and so had to pile a lot of weight on the w= ing to get the squeeze out and proper wing shape.  A source of vibra= tion would help. 
 
As it was, I had lots of lead bags and 5 gallon buckets filled with = rocks for both wings, and  used them all on one wing to get the stuf= f to squeeze out and get the proper wing shape.  Saddles were pulled= down tight, but bent.  ALL the rocks in buckets were piled on top o= f the lead bags in between the wing saddles of the first wing to get= everything to settle into place.  The second wing skin had to wait = for another day. 
 
As I recall, we used a crew of four or five  to mix epoxy, appl= y, put down the skin, and then lock it in place and them pile up buckets.=   I would have more were I to do it again, with a good briefing at t= he start.
 
My guess was that we had over 500 pounds of weight to squeeze out th= e epoxy/flox mix.  Temperature makes a huge difference in viscosity = and squeeze out.  You want cool to prevent the stuff cooking off too= soon, but warm to make it thin.   Speed is important  and= having lots of spreading tools and hands is mandatory.
 
Post inspection looking through the holes Into tanks and with mirror= s into the fuel fill port, we found a nice squeeze out, but no drips of e= xcess, so the estimate of 0.020 inch thickness for the bond line worked o= ut OK.
 
Fred Moreno
 
 
 
 
-= ------Original Message-------
 
Date: 14/08/2013 7= :51:51 PM
Subject: Wing clos= ing epoxy
 
I am preparing to clo= se a set of wings and have some questions about Hysol epoxy.  I've r= eviewed previous posts and there hasn't been much said for awhile, perhap= s because wings are coming from factory closed now.

I went to Aircraft Sp= ruce and said "I need six quarts of Hysol."  They sold me six quarts= of Hysol.  I used it to epoxy in a fuel drain and probe and was ask= ed by Matthew Colliers why it wasn't blue.  So, I looked closer at m= y manuals and saw that it calls for epoxy and flox if temperatures are be= low 70 degrees and Hysol 9339 if temperatures are above 70 degrees.  = ;I then went to the Lancair website and found they don't even carry Hysol= 9339, but have changed to Hysol 9360.  The product Aircraft Spruce = sells is Hysol 9430.  Lancair tech support says they don't know why = 9360 is specified.  "That was selected by the guy before me."=

Aircraft Spruce says = - 

"This new and improved Hysol = glue replaces the old EA-9410-2 glue. EA-9430 has the same characteristic= s as the EA-9410, but has a 50 minute pot life instead of the 30 minute p= ot life of the EA-9410 at 77=C2=B0F. Used extensively in the Strojnik S2A= sailplane and many other homebuilts."

Locktite tech support and t= he data sheets show the pot life, tensile and shear strenght to be almost= identical.  The one difference I can find is that the 9360 specifie= s shear at different temperatures while 9430 specifies the shear strenght= only at 77 degrees.  The guy from Locktite couldn't explain the dif= ferences, and said "they appear to be very similar products".  Can a= nyone tell me what makes the 9360 product better suited for Lancair wings= ?  Is there a reason not to use the six quarts of 9430 in my fridge?=

Mike Baudhuin
 
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