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ADVANCED HYPALON REPAIRS INSTRUCTIONS
1. FIELD LEVEL REPAIRS.
The standard repair kit supplied with boats is based on a one part adhesive system. This is principally to avoid the need to supply the second part of the adhesive system, namely the hardening agent.
The one part adhesive system is suitable for most field repairs such as abrasion or pinholes. Where the seam is under load, such as a 100mm tear in the tube a two part glue system must be used.
2. ADVANCED REPAIRS.
2.1. The advanced repair method is based on a two part adhesive system. The adhesive is exactly the same as the one part system, but is a hardening agent is added.
SAFETY
“WARNING’:
The hardening agent is classed as a Dangerous material and should be used with considerable care.
If it gets on you skin it must be washed off with water immediately and protection should be made to prevent it getting in the eyes.
Avoid breathing vapour emitted from the adhesive.
Do not use solvents near open flame.
Allow the adhesive to dry for 24 hours before applying maximum stress.
2.1a GLUE MIXING
Mix 20 parts adhesive to 1 part of Hardener. (by volume). Stir thoroughly. Unmixed adhesive has a shelf life of 6 months. Once hardener is mixed with adhesive it has a pot life of 1 1/2 hours. (The exact hardener to glue is not very critical 4-9%)
1.1 PUNCTURES OR ABRADED AREAS.
1. Cut a patch, with well rounded corners, that extends 25 mm beyond damaged area.
2. Place patch over damaged area and trace around the edge of the patch to show where to buff and glue. If more than one patch is being applied it is useful to number the patch and the damaged area.
3. Buff both surfaces to be bonded with 120 sand paper or grit flapper wheel to remove the skin on the outer surface of the fabric.
The fabric should be buffed until the milky surface is removed and a rich velvety “clean” rubber appears. This is MOST IMPORTANT. The outer “whitish” skin must be completely removed. If you cut through to the textile, you have gone to far. Practice on a scrap of fabric!!!!
“IMPORTANT”: Under no circumstances continue if the nylon reinforcing appears.
4. Clean both surfaces with a suitable cleaning fluid. (MEK or toluene). Moisten a cloth with the solvent then rub the area to be glued. Allow to dry thoroughly.
5. Apply adhesive to both surfaces, with a small brush (or spatula) and allow to dry for at least 45 minutes. Overnight drying is preferred. This layer is known as preglue or undercoat.
6. Clean both surfaces with a suitable cleaning fluid. As above. Allow to dry thoroughly.
7. Apply adhesive to both surfaces, with a small brush (or spatula) and allow to dry until the adhesive becomes touch dry. Approximately 15 minutes.
8. Position the patch over the prepared area and contact one corner, then allow the patch to fold (not flop) down over the remaining area.
9. Press the patch down firmly and roll with a roller or suitable blunt object. Pressure is a critical aspect of achieving a strong bond.
10. The new patch can be lightly inflated immediately. Full strength will be achieved in five days.
2 SERVICE STATION LEVEL REPAIRS.
All work should be done indoors away from drafts, direct sunlight, in the temperature range 60 to 80 degrees Fahrenheit and where the humidity does not exceed 70 %
SAFETY
“WARNING” : Avoid breathing vapour emitted from the adhesive.
Do not use solvents near open flame.
Allow the adhesive to dry for 24 hours before applying maximum stress.
Avoid allowing the Adhesive hardening agent to come in contact with you skin. If a spill does occur wash with copious quantities of water for at least 10 minutes. If this does not result in total comfort consult a doctor on how to deal with Iscoyanate.
Do not use the adhesive mixture if it is more than 4 hours old.
2.3 INTERNAL PATCHES
Where a puncture exceeds 50 mm in length an internal and external patch should be used.
The technique used for field repairs apply but an additional patch is placed on the inside of the damaged area. This calls for special techniques to ensure the internal patch is correctly positioned.
1. Prepare the internal patch and buff an area on the inside of the tube 10 mm greater than the patch.
2. Lay the torn edges, of the tube, together and match mark both edges every 50 mm.
3. Place patch in position under the damaged area and trace a line along the centre line of the patch to show where the tear will lie. Then transpose match marks onto the patch. This will help with the alignment of the patch when the bond is being made.
4. Allow preglue to dry over night. In order to insert patch inside tube without contaminating the adhesive with your fingers, roll the patch in a layer of thick polyethylene sheet. Insert it, then, using the match marks, align the patch; contact one corner then proceed to fold out the patch over the glued area.
5. After rolling, inflate and check that patch is airtight. Proceed with external patch.
2.6 ABRASION
Where the barge fabric is chafed to a stage that the internal nylon reinforcing appears, a protective patch MUST BE APPLIED to restore strength and prevent liquid penetrating the fabric.
4 REPAIR MATERIALS
Only Lancer approved materials are to be used for repairs. Lancer repair procedures must be observed for all repairs.
MATERIALS
Adhesive Hypalon 60ml Tube
Adhesive Hypalon 500ml Tin
Adhesive Hypalon 1000ml Tin
Adhesive Hardener 100ml Bottle
Cleaning Fluid Hypalon (MEK) 1000 Tin
Hypalon 840 Denier 1500mm wide by the meter
Hypalon 1680 Denier 1500mm wide by the meter
Hypalon 840 Denier cut to size
Hypalon 1680 Denier cut to size
Hypalon is also available in assorted sizes as off-cuts.
Neoprene 1mm thick 1200mm wide by the meter
Neoprene 1mm thick cut to size
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