Table of contents

Teams that do this

Baja, FSAE, CUAir, CUsail, Resistance Racing, CU Solar Boat

Chemicals involved & MSDS for each (should also be included in confluence SDS) 

Safety Gear

• Nitrile gloves
• Gray (VOC) masks/respirator

Step by step

Duratec is a thick black liquid surface primer that we mix with a chemical catalyst called MEKP. Duratec fills in the small holes in the foam, and allows us to sand the plugs to a higher grit, ultimately allowing for a smooth, shiny finish for the plugs. 

1. Safety precautions are critical when spraying Duratec. Duratec should only be sprayed in the paint booth with the air circulation on. Before going into the paint booth, assemble all needed materials, including: cups, stir sticks, plastic-wrap protected scale, Duratec, lacquer thinner, MEKP and HVL spray gun. You must also wear a vapor-protective respirator and gloves.
2. Before spraying the Duratec, use the air tool to get rid of all the dust/sanded particles on and around the panel (the paint booth can build up a lot of dust and debris as well). Then mix the Duratec with 10% by mass lacquer thinner and 2% by mass MEKP. For example: 300g Duratec, 30g lacquer thinner, 6g MEKP. 
3. Spray the Duratec on to the foam plugs in long, even strokes.  Spray 2-3 coats of Duratec, ensuring the plug is completely covered and will be able to be sanded down without hitting the previous layer. Leave the Duratec-covered plugs in the paint booth for 6 hours to cure (see photo).