Fuel Probe Installation

Figure 5 3 BID probe mount reinforcement Aluminum probe mount Use a hysoUflox mixture lo pol aluminum probe mount into BL 25.5 rib (Inboard Installation) or BL 165 (outboard installation). 3 BID probe mount reinforcement BL 25.5 rib / 2 BID probe mount reinforcement \2 BID probe mount reinforcement A/CUP Lancnir Intemntionnl Inc., Represented by Neico Aviation Im., Copyright O 1995, Redmond, OR 97756 Hl2. A probe guide extension is helpful on the BL 114 (inboard installation) or the BL 38 (outboard installation) rib. The guide is shaped like a funnel and will be very useful if you ever have to take the probe out after the wing has been closed. Form the guide extension by applying release tape to a small plastic funnel. Use 3 BID to form the guide on the funnel. Hl3. When the 3 BID has cured, pop the guide extension loose from the funnel and trim as necessary so the extension will fit flush with the plastic guide in BL 114 or BL 38. See Figure 6. H14. Bond the guide extension to the guide and the proper rib with 2 BID. Be sure that there is a smooth transition from the inside of the guide extension to the plastic guide. Probe Guide Extension Figure 6 rOUTBD A/CUP ~ BL 38, 52, 76 or 3BID funnel BL 52, 76, 114 (extended tank) NOTES: BL 114 or BL 38 (extended tank) Hysol & Flox 1. Make sure the bottom skin is placed so that it does not interfere with the fuel pick up, strainer or drain. 2. Use the probe to install all plastic sleeves. 3. Slide the sleeves and mounting bushing on the probe and bond into each rib with hysol. 4. Cut the hole for the sleeve larger on outboard rib skin. Lancair Int.crnntfonal Inc., Repre:rnnt.ed by Neico Aviation Inc., Copyright@ 1995, Redmond, OR 97756 Manual.supplement for Extended Fuel Tanks ~~"":;~;;;;=~~:=f).~ ... =--=l,=~==.4==1.=,R_===-®__.:N~_!____J·li81J---~-~-T-~-~-R_E_D__~F-~-EV_~_IN_S_T_~_i_~_-l_;_I~-N--+-t-,f--11 Lnncair Int.ernationnl Inc., Reprcscnt.ed by Neico Aviation Inc., Copyright© 1996, Redmond, OR 97756 EXTENDED FUEL TANK INSTALLATION This is the only extended fuel tank option for the Lancair N that has been engineered and authorized by the factory. A computer flutter analysis has proved this option to be airworthy. Utilizing the extra wing area described in this section will add about 5 gallons to each wing's fuel capacity. Extended Fuel Tanks Figure EF-1 BL 25.5 I CONTENTS - = Standard fuel bays = Extended fuel bays A. BL 165 RIB INSTALLATION B. VENT AND DRAIN SYSTEM CHANGES C. RELOCATING FUEL FILLER NECK BL 114 I D. ELECTRIC AND PITOT TUBE MODIFICATIONS E. TIE DOWN MODIFICATIONS Lancair Int.ernntional Inc., Rupreimnt.ed by Neico Aviation Inc., Copyright ID 1996, Redmond, OR 97756 BL147 F. SEALING BL 114 NUTPLATES A. BL 165 RIB INSTALLATION The extended fuel option requires installation of an additional rib at BL 165. This rib is made from 2 ply per side prepreg. · BL 165Rib Figure A:1 BL147 BL 114 BL 165 I I Ill n f -- ' --- <s.. ----.:.-==-.s--"'-="":. ----=.:- =-- -- ~~~~~-=-~-~- . I I BL 171 Al. Cut cardboard rib templates (one nose rib, one main rib) that will fit in the wing at BL 165. A2. Use the templates you just made to cut BL 165 nose and main ribs from 2 ply per side, 1/4" thick prepreg sheet. Fit the ribs into your wing. A small notch is required over the vent line and the plastic electric tube. A3. Use 40 grit to sand the areas of the wing skin and spars where the BL 165 rib will be bonded. Clean these areas with MC. ~IP.Alia® NI [~]: LANCAIR I REV. 1/ 5-1-93 \-,< c.....,;- •~""'-- EXTENDED FUEL INSTALLATION P< Luncair Int.ernationnl Inc., Repre11ent.ed by Neita Aviation Im:., Copyright(!) 1mrn, Redmond, OR 97756 B. VENT AND DRAIN SYSTEM CHANGES Additional vent and drain holes mnst be added to the BL 14 7 ribs, the aft fuel bay web, and the main spar. It is also required to shorten the aluminum vent line at the top of the tank. Bl. Grind vent and drain holes in the BL 147ribs as shown in Figure B:l. These holes should be shaped like a half circle, just like the vent and drain holes you ground out when initially installing the wing ribs. B2. Push back or grind out the core to form troughs around the :vent and drain holes you have just ground. Fill around the holes with a 50/50 micro/fl ox mixture to seal the core areas from fuel. Vent and Drain Holes in BL 147 Rib Figure B:l Vent holes (3/4" dia.) BL 147 rib A/Cup Aft fuel ba web I II,, 11I, NOTE: This drawing shows the wing upside-down as it sits in the jig. Drain holes (1" dia.) ~c:2"';;~:?:~~~§A~•;;;;;,l'.,~~§.8~1..~~~~~®~N~~-_Jl[~s~~··~==~=~=T=~=~=R=E=D=~F=:=v=~=IN==S=T=~=/=~=-l=;=I~=N===~~~Lancair International Inc., Represented by Ncico Aviation Inc., CopyrighlO 1996, Redmond, OR 97756 B3. Grind vent and drain holes in the aft fuel bay web between the BL 114 and 14 7 ribs as shown in Figure B:2. B4. Remove the core from around the vent and drain holes you ground in the fuel bay web and fill these areas with a 50/50 micro/flox mixture. Vent and Drain Holes in the Aft Fuel Bay Web Figure B:2 BL Drain holes Air1r4 / (1"dia.)~ up Aft fuel bay web Top wing skin / Outbd Vent holes/ (3/4" dia.) BL 147 I NOTE: This drawing shows the wing upside-down, as it sits in the jig 1 ◄◄ GII----- 17"'------.i Lancair lnt.ernationnl Inc., Rcpre,mntcd by Ncico Aviation Inc., Copyright ID 1996, Redmond, OR 97756 B5. Grind a vent hole in the main spar web as shown in Figure B:3. B6. Remove the core around the vent hole in the main spar and fill around the hole with a 50/50 micro/flax mixture. BL 165 nose rib Vent Hole in Main Spar Figure B:3 Mai~ ~·¥ 3/8" ~ Vent hole BL 165 rib B7. Shorten the aluminum fuel vent line so its inboard end stops at BL 164.5, 1/2" inboard of the BL 165 rib. Apply 2 BID to secure the vent line to the inboard face of the BL 165 rib,just as you had done at the BL 14 7 rib. Refer to Chapter 6, Figure 6:E:l. BS. Fill the vent line hole in the BL 147 rib with epoxy/flax. This will protect the rib from fuel. C. RELOCATING FUEL FILLER NECK If you have already installed the fuel filler necks inboard of the BL 147 ribs, you will have to relocate them to just inboard of the BL 165 ribs. If you haven't yet installed the fuel filler necks, so much the better, disregard Steps Cl-C9 and install the filler necks at the new location shown in Figure C:2. C 1. To relocate a fuel filler neck, grind away the Hysol and fiberglass from around the edges of the neck. Use a wood chisel to carefully pry under the edge of the neck and remove it from the top wing skin. C2. Now you have a round hole in your top wing skin that does nothing. You must patch this opening securely. Use 40 grit to sand the area of the top wing skin where the filler neck was bonded. Clean this area with MC. C3. Apply release tape to one side of a piece of cardboard. The cardboard should be large enough to cover the filler neck hole. C4. Use instant glue or tape to secure the cardboard piece to the outer surface of the top wing skin. The release tape should be against the wing surface and covering the filler neck hole. G) Patching Filler Neck Hole Figure C:1 Remove steel filler neck"--. "')~--~\_ Cl~======== lu ,11 , 11 , , , , , ui II Ji 1 , l Topwi g skin G) 3 BID p~h "p"',"ij"'i-,1"'1=,-,"'u"'l"'l""'I'"11..,1""11-,"',""ii..l "-.._ Top wing skin llTI 3 f 11 111 I I 111/ II I ~ G) 3 BID over foam 11 1111111111111111 Lnm:air Int.emntional Inc., Represented by Neico Aviation Inc., Copyright© Hl96, REdmond, OR 97756 ' Cardboard w/release tape C5. Apply 3 BID to the area where the filler neck was bonded, covering the filler neck hole. This BID patch replaces the outer laminate of the original skin. The cardboard release will form the BID to the proper shape. C6. · To replace the core, use a round piece of 1/4" thick Clark foam. Bond the foam into the filler neck area with a thin epoxy/micro mixture. C7. To finish the patch, apply another 3 BID to the Clark foam area, extending onto the original inner laminate by 1". Apply a thin coat of epoxy/micro to the Clark foam area before laying the 3 BID. With a little microballoon smoothing on the outer surface of the wing, the patch will be complete. CS. Clean off the fuel filler neck by chipping off the old Hysol and fiberglass. Use 40 grit to rescuffthe bonding areas of the filler neck. Clean the filler neck with MC. C9. Install thefuelfillerneckatthenew location given in Figure C:2. Refer to Chapter 6, Section G for instructions on installing the filler neck. II New Filler Neck Location Figure C:2 Standard filler neck locati n BL 1 7 3 3/4" 12" BL 1 5 1-o La11cair Internutfonal Inc., Rllprn.sen!.etl by Neico Aviation Inc., Copyright© 1996, Redmond, OR !17756 BL 171 D. ELECTRIC AND PITOT TUBE MODIFICATIONS The thin walled, black plastic electric tube now must run through the fuel area between BL 114 and 165. Since the tube is not fuel proof, you must cover it with BID. The aluminum pi tot tube line0 is also now immersed in the extended fuel area of the left wing. Dl. If you have already installed the black plastic electric tubing, it will be secured to the surface with small sections of BID. To seal the tube in its harsh new environment of the fuel tank, you must cover the tube with 1 BID, overlapping onto the top wing skin 1" on both sides of the tube. Be sure to sand and clean both the plastic tube and the surrounding wing skin and rib surfaces. Sealing Electric Tube in Fuel Area Figure D:l Standard method of securin tube. Aft fuel bay web'------... Plastic electric J tube Topwlngskln / New method of securing and sealin tube. Aft fuel bay web Plastic electric tube rib . ' 1 BID securing laminate covers entire tube. "'5ttin,._ Lancair Intemntional Inc., Represunt.Jd by Neico Aviation Inc., Copyright© 1996, Redmond, OR 97756 D2. If you have already routed your pi tot tube line and installed the plastic grommets in the BL 114 and BL 14 7 ribs, you will have to remove those grommets. The pitot tube should be potted into position on those ribs using epoxy/flax, as shown in Figure D:2. D3. Use 2 BID to reinforce the areas where the aluminum pitot tube line passes through the BL 114, BL 147, and BL 165 ribs. There is no reason to cover the entire length of tube with BID because the aluminum is impervious to fuel. Pitot Tube Line Reinforcement FigureD:2 Aft fuel bay web Aluminum pitot line 2 BID 1117..:::..,::=~ \ \ ' ' ' Plastic grommet has been removed and the aluminum line is potted into the BL 147 and 165 ribs with flox and 2 BID. -, , 2 BID ' ' / /,,. \ \ \ \ -- 2BID ~ BL 147 rib (BL 165 similar) L.ancair Int.ernational Inc.., Rnpros1mled by Neico Aviation Inc., Copyright© 1996, Redmond, OR 97756 E. TIE DOWN MODIFICATIONS Because the tie down is mounted in the extended fuel section, it must be sealed off to prevent leakage. El. Form a small piece of Clark foam into a shape that will surround the top portion of the tie down assembly, where the tie down pin will extend through its housing and lock. Bond this foam piece in position with epoxy/micro. Make sure you can still get the tie down pin in position and locked. See Figure E:1. Forming Pin Housing Cover Figure E:1 Tie down pi Tie down we dment 2 BID, applied over a foam piece. The foam should be hollowed out to accomodate the tie down pin. Top wing skin in spar E2. Use 40 grit to sand the area around the foam piece you just installed. Clean this area with MC. E3. Apply 2 BID to the foam piece, extending the BID 1" onto the surrounding surfaces. This should seal off the top of the tie down assembly. Lancair Int.ernat.ional Inc., Represented by Neico Aviation Inc., Copyright© 1996, Redmond, OR 97756 E4. To seal the bottom of the tie down· assembly, a capstrip is needed. Apply a layer of release tape to the inner surface of the bottom wing skin in the tie down area. E5. Apply a 2 BID capstrip to the inner surface of the bottom wing skin that will cover the area around the tie down shown in Figure E:2. Tie Down Capstrip Figure E:2 BL147rib~ Tie down capstrip ~ Note: Size of capstrip can vary.1" surrounding the tie down shaft would be sufficient. E6. Apply some thick epoxy/flax around the tie down area that will secure the capstrip in position. E7. Carefully lower the bottom wing skin into position and weight it down in the tie down areas. ES. After the micro and 2 BID capstrip have cured, remove the bottom wing skin carefully to avoid breaking loose the capstrip. c:.,m,CA/A® w 1ai•r--~-~-T-~_!_R_E_D_F·~-E-VL-__IN_S_T_~-/-~--l-:-13_o_N_-1,----,1 Lancair Jnt.ernntional Inc., &presented by Neico Aviation Inc., Copyright O 1996, Redmond, OR 97756 Securing Tie Down Capstrip Figure E:3 2 BID capstri~ 2 BID securing tie down capstrip Top wing skin ✓ nspar E9. Secure the capstrip in position with 2 BID, overlapping onto the surrounding surfaces by l". Be sure to sand and clean the areas where the 2 BID is applied. This capstrip should seal off the bottom portion of the tie down assembly. Lancair lnternntional Inc., Repmsented by Neko Aviation Inc., Copyright ID 1996, Redmond, OR 97756 F. SEALING BL 114 NUTPLATES There are four nutplates riveted to the outboard face of BL 114 rib that are used to secure the bellcrank brackets. These nutplates must be covered to avoid fuel leakage. Fl. Cut a piece of 1/2" thick Clark foam that will cover the four nutplates on the outboard side of the BL 114 rib. You'll have to sand little depressions in the foam to accomodate the nutplates and allow the foam to rest flat against the rib. F2. Use epoxy/micro to bond the Clark foam cover to the outboard face of the BL 114 rib. Be sure Y.OU don't foul the nutplate threads with the mien;>. It is a good idea to screw the bolts into the nutplates to protect the threads. Foam Nutplate Cover Figure F:l:a lnbd Fwd._J BL 1 4 rib 2 BID covers Clark foam and overlaps 1" onto surrounding surfaces Aftsp~ Clark foam hollowed out over nutplates Lancuir International Inc., Repres1mted by Ncico Aviation Inc., Copyright O l!l96, Redmond, OR 97756 'I 'I ', :, " 1rcl-------.... "" ",, I' 1 Foam Nutplate Cover Figure F:l:a Capstrip AJCup / BL 114 rib,/ ' Core was removed in Chapter 6, Section 0. 2 BID covering foam and overlapping 1" onto surrounding surfaces Clark foam, hollowed out over nutplates 8 BID rib reinforcement, / applied in Chapter 6, .Ji(' Section 0 ---=-~1 It\ JI\I \\}ll\l\1 \Ill Ill ll\ '- 1111\ I lilt\ I llf Top wing skin F3. Round the edges of the foam nutplate cover and form micro radii in the corners. F4. Spread a thin coat of epoxy/micro onto the foam nutplate cover surface, then apply 2 BID, overlapping l" onto the surrounding surfaces. You'll only be able to overlap onto the capstrip about 1/2", but that is sufficient. F5. Now be sure you can bolt the bellcrank brackets in place and not damage the Clark foam nutplate cover. Lam:nir International Inc., Represented by Neico Aviation Inc., CopyrightO l!l96, Redmond, OR 97756 5252 Kearny Villa Way San Diego, CA. 92123 (619) 576-9900 EPOXIES CONSTRUCTION SPECIALTIES LAMINATING AND TOOLING ENVIRONMENTAL CONTAINMENT Quality products since 1989 JEFFCO 130·7 HIGH PERFORMANCE EPOXY RESIN LOW VISCOSITY DESCRIPTION: High performance multifuctional epoxy resin blend containing minimal reactive diluent content for maximum property retention. Resin allows fast and efficient wetting of reinforcement materials. 100% solids, very clear. Highly resistant to crystallization. USES: High performance composites, low viscosity filament winding compounds, hand lay up laminating, tooling, casting and chemically resistant flooring. PROPERTIES OF 1307 RESIN: Viscosity: 1800 - 2000 cps EEW: 185 - 195 Color: 2 (max) WeighUGal: 9.4 - 9.6 MIXING: Use JEFFCO 1307 epoxy at the recommended temperature range of 50° - 100° F. Use of'JEFFCO 1307 below 45° Fis NOT recommended. All'standing water must be removed. Surfaces must be free of contaminants such as dirt, oil or grease. Mold surfaces must be waxed or otherwise released prior to application of epoxies. Proportion JEFFCO resin and hardener in accordance with instructions on hardener label. Mix resin and hardener thoroughly for 3-5 minutes being certain to scrape bottom and sides of mixing container. Mix no more material than may be applied in 10 - 15 minutes or before the expiration of pot life of the system, whichever is shorter. CURING: Keep application at the recommended use temperature for a minimum of 24 hours. Full properties are developed in 7 days at ambient temperatures. See hardener data for specific cure schedules and properties. HOW SUPPLIED: Gallon bottles at 9# net, Pails at 40# net, 55 Gallon drums at 500# net. Sold FOB San Diego, CA. or through authorized JEFFCO distributors. JEFFCO epoxies are moderately priced. DOT - not regulated. MATERIAL SAFETY DATA SHEET Jeffco Products, 5252 Kearny Villa Way, San Diego, CA. 92123 MSDS: JEFFCO 1307 (RESIN COMPONENT) Effective Date: 1/4/94 Date Printed: 1/8/94 1. INGREDIENTS Emergency Phone:(619) 576-9900 lnfotrac:(800) 535-5053 Reaction products of Epichlorohydrin and Bisphenol F 85% CAS # 28064-14-4 Remaining ingredients are trade secret This document is prepared pursuant to the OSHA Hazard Communication Standard (29 CFR 1910.1200) in addition, other substances not Hazardous per this OSHA Standard may be listed Where proprietary Ingredient shows the identity may be made available as provided in this standard. 2. PHYSICAL DATA BOILING POINT: not applicable VAP PRESS: not applicable VAP DENSITY: not applicable SOL. IN WATER: none SP. GRAVITY: 1.16 APPEARANCE: water-white to yellow liquid to semi-solid ODOR: faint epoxy odor 3. FIRE AND EXPLOSION HAZARD DATA FLASH POINT: 480°F METHOD USED: PMCC FLAMMABLE LIMITS LFL: not applicable U FL: not applicable EXTINGUISHING MEDIA: foam, CO 2 , dry chemical FIRE AND EXPLOSION HAZARDS: none FIRE-FIGHTING EQUIPMENT: Wear positive pressure self-contained breathing apparatus. MSDS: JEFFCO 1307 PAGE 2 4. REACTIVITY DATA: STABILITY: (CONDITIONS TO AVOID) Excess heating over long periods of time degrades the resin. INCOMPATIBILILTY: (SPECIFIC MATERIALS TO AVOID) Base. HAZARDOUS DECOMPOSITION PRODUCTS: The by-products expected in incomplete pyrolysis or combustion of epoxy resins are mainly phenolics, carbon monoxide and water. The thermal decomposition products of epoxy resins therefore should be treated as potentially hazardous substances and appropriate precautions should be taken. HAZARDOUS POLYMERIZATION: Will not occur by itself but masses more than 1 pound of product plus aliphatic amine will cause irreversible polymerization with considerable heat buildup. 5. ENVIRONMENTAL AND DISPOSAL INFORMATION ACTION TO TAKE FOR SPILLS/LEAKS: Soak up in absorbent material and collect in suitable containers. Residual may be removed using steam or hot soapy water. DISPOSAL METHOD: Burn in adequate incinerator or bury in an approved landfill; in accordance with local, state and federal regulations. 6. HEALTH HAZARD DATA: EYE: Minor transient irritation. No corneal injury likely. SKIN CONTACT: May cause allergic skin reaction in susceptible individuals. Prolonged exposure not likely to cause significant skin irritation. Repeated exposure may cause skin irritation. SKIN ABSORPTION: A single prolonged exposure is not likely to result in the material being absorbed through skin in harmful amounts. The LD 50 (rat) greater than 4000 mg/kg. No hazards anticipated from ingestion incidental to industrial exposure. INHALATION: Vapors are unlikely due to physical properites. Not a problem unless heated to high temperature. MSDS: JEFFCO 1307 PAGE 3 SYSTEMIC AND OTHER EFFECTS: Except for skin sensitization, repeated exposures to low molecular weight epoxy resins of this type has been reported to produce skin cancer in a highly sensitive strain of mice. However, high levels of impurities compromise the validity of the findings. Epoxy resin that is representative of current manufacturing processes is not believed to be a cancer hazard to humans. Results of mutagenicity test in animals have been negative. It has been shown to be negative in some in vitro mutagenicity test and positive in others. 7. FIRST AID: EYES: Irrigation of the eye immediately with water for five minutes is good safety practice. SKIN: Contact will probably cause no more than irritation. Wash off in fiowing water or shower. Wash clothing before reuse. INGESTION: Low in toxicity. No adverse effects anticipated by this route of exposure incidental to proper industrial handling. INHALATION: Remove to fresh air if effect occurs. Consult medical personnel. NOTE TO PHYSICIAN: No specific antidote. Supportive care. Treatement based on judgment of the physician in response to reactions of the patient. 8. HANDLING PRECAUTIONS: VENTILATION: Food room ventilation usually adequate for most operations. RESPIRATORY PROTECTION: For brief contact, no precautions other than clean body- covering clothing should be needed. Use impervious gloves when prolonged or frequently repeated contact should occur. EYE PROTECTION: Use chemical goggles. MSDS: JEFFCO 1307 PAGE 4 9. ADDITIONAL INFORMATION SPECIAL PRECAUTIONS TO BE TAKEN IN HANDLING AND STORAGE: Practice good caution and personnel cleanliness to avoid skin and eye contact. Avoid breathing vapors of heated material. 10. NFPA HAZARD RATING 4 = EXTREME 3 = HIGH 2 = MODERATE 1 = SLIGHT 0 = INSIGNIFICANT 11. REGULATORY INFORMATION HEALTH FIRE REACTIVITY SPECIFIC 1 1 0 STATUS ON SUBSTANCE LISTS: The concentrations shown in this document are maximum or ceiling levels (expressed in wight %, unless otherwise specified) to be used for regulations. Trade Secrets are indicated by "TS". FEDERAL EPA: COMPREHENSIVE ENVIRONMENTAL RESPONSE COMPENSATION and LIABILITY ACT of 1980 (CERCLA): N/A SUPERFUND AMENDMENTS and REAUTHORIZATION ACT of 1986 (SARA) TITLE Ill: N/A EPA HAZARD CLASSIFICATIONS: Acute Chronic Fire Pressure Reactive Hazard Hazard Hazard Hazard Hazard no no no no no MSDS: JEFFCO 1307 PAGE 5 Section 313 requires submission of annual reports of release of toxic chemicals that appear in 40 CFR 372 (for SARA 313). This information must be included in all MSDSs that are copied and distributed for this material. Components present in this product at level which could require reporting under the statue are: Chemical Name CAS Number % By Weight NONE If you are unsure if you must report more information, call the EPA Emergency Planning and Right-To-Know Hot Line: 800-535-0202 or 202-479-2449. TOXIC SUBSTANCES CONTROL ACT (TSCA): The components of this product are contained on the chemical substance inventory list. OTHER REGULATORY INFORMATION: None known to this firm. The information herein is given in good faith, but no warranty expressed or implied is made. JEFFCO PRODUCTS urges suppliers and users of this product to evaluate its suitability and compliance with local regulations as JEFFCO PRODUCTS cannot forsee the nature of the final application nor final location of usage. DOT SHIPPING INFORMATION: Not regulated. END OF MSDS JEFFCO 1307 5252 Kearny Villa Way San Diego, CA. 92123 (619) 576-9900 EPOXIES CONSTRUCTION SPECIALTIES LAMINATING AND TOOLING ENVIRONMENTAL CONTAINMENT Quality products since 1989 JEFFCO 3102 FAST ROOM TEMP EPOXY HARDENER DESCRIPTION: Aliphatic mannich base hardener. Fast setting, even in thin films. Good low temperature cure. Excellent chemical resistance. Fast wetting of fiberglass reinforcements. Easy to use 4:1 mix ratio. 100% solids. High HOT with post cure. DOT: Not Regulated. USES: Hand lay up laminating, marine construction, RTM, vacuum bagging, tooling, fairing compounds, "hot" coating or sealing of wood or porous substrates, chemically resistant coatings. PROPERTIES OF 3102 HARDENER: Viscosity @ 77F, cps Weight per Active H Color (Gardener) Weight per Gallon Mix Ratio, parts per 100 of resin Pot Life (150 grams) Thin Film set Time, hours 1500 50 6 9.0 Lbs 25 - 26 11 - 15 minutes 1.5 CURED PROPERTIES WITH 1301. 1303. 1304T or 1308 RESIN: (cure schedule: Gel@ ambient+ 2 hours@ 212°F or 7 days at 77°F) HOT (ASTM 0648-264) F Service Temperature F Barco! Hardness Flexural Strength, psi Flexural Modulus, psi Tensile Strength, psi Tensile Modulus, psi Elongation % 214 225 + 84 17,900 377,000 9,450 493,000 2.5 HOW SUPPLIED: Quart Bottles at 2# net, Gallon Bottles at 8# net, Pails at 40# net, 55 Gallon Drums at 450# net. Shipped FOB San Diego, CA. or through authorized JEFFCO distributors. JEFFCO 3102 HARDENER, pg-2 CHEMICAL RESISTANCE (3 WEEK IMMERSION) REAGENT % WEIGHT GAIN (OR LOSS) Xylene Toluene 1, 1, 1 Trichloroethane MEK EB (Ethylene Glycol Monobutyl Ether) Ethyl Alcohol Methyl Alcohol Water (distilled) 5% Detergent Solution 10% Sodium Hydroxide 50% Sodium Hydroxide 10% Sulfuric Acid 70% Sulfuric Acid 10% Hydrochloric Acid 20% Nitric Acid 10% Acetic Acid Skydrol Synthetic Gasohol 0.7 2.8 0.9 nr * (OK for splash service) 6.1 1.0 8.5 0.5 (< 0.02 in 24 hours) 0.5 0.4 (0.1) 1.7 1.0 1.1 1.4 7.3 0.0 12.4 (LEGEND nr = not recommended, - not tested) Note: Above tests are performed on panels using JEFFCO 1301 Epoxy resin cured with 26 PHR JEFFCO 3102 Hardener - gel@ 77° F + 2 hours@ 212°F + 7 days@ RT. JEFFCO PRODUCTS 5252 Kearny Villa Way, San Diego, CA. 92123 - (619) 576-9900 MATERIAL SAFETY DATA SHEET JEFFCO PRODUCTS, 5252 Kearny Villa Way, San Diego, CA 92123 Emergency Phone: (619) 576-9900 lnfotrac:(800) 535-5053 MSDS: JEFFCO 3102 (HARDENER COMPONENT) Effective Date: 2/14/94 Date Printed: 2/14/94 1. INGREDIENTS Phenol < 15 % Triethylene Tetramine· < 05 % Formaldehyde Polymer with Phenol and TETA > 85 % CAS# 108-95-2 CAS# 112:24-3 CAS# 32610-77-8 This document is prepared pursuant to the OSHA Hazard Communication Standard (29 CFR 1910.1200) in addition, other substances not Hazardous per this OSHA Standard may be listed. Where proprietary Ingredient shows the identity may be made available as provided in this standard. 2. PHYSICAL DATA BOILING POINT: VAP PRESS: VAP DENSITY: SOL. IN WATER: SP. GRAVITY: APPEARANCE: ODOR: N/A N/A N/A Slightly soluble 1.08 Amber colored liquid Amine odor 3. FIRE AND EXPLOSION HAZARD DATA FLASH POINT: 277° F METHOD USED: PMCC FLAMMABLE LIMITS LFL: N/A UFL: N/A EXTINGUISHING MEDIA: Use alcohol foam, CO 2 , dry chemical FIRE AND EXPLOSION HAZARDS: Use full protective clothing (see Section 8) FIRE-FIGHTING EQUIPMENT: Use a positive pressure, self-contained breathing apparatus. MSDS: JEFFCO 3102 PAGE 2 4. REACTIVITY DATA: STABILITY: (CONDITIONS TO AVOID) Can autoignite in air at approximately 572°F,300°C. INCOMPATIBILILTY: (SPECIFIC MATERIALS TO AVOID) Epoxy resins under uncontrolled conditions. HAZARDOUS DECOMPOSITION PRODUCTS: Nitrogen oxides when ourned. HAZARDOUS POLYMERIZATION: Will not occur. 5. ENVIRONMENTAL AND DISPOSAL INFORMATION ACTION TO TAKE FOR SPILLS/LEAKS: Large spill -- dike up and pump into appropriate containers. Small spill - use noncombustible absorbent material/sand and shovel into suitable containers. DISPOSAL METHOD: Large quantities should be recovered. Collect small quantities in waste metal drums and seal for removal to an approved landfill, or incinerate in accordance with local, state and federal regulations. 6. HEALTH HAZARD DATA: EYE: May cause severe irritation with corneal injury, which may result in permanenet impairment of vision, even blindness. Vapors may irritate eyes. SKIN CONTACT: May cause severe injury to skin following prolonged or repeated contact, and. may cause skin sensitization or other allergic res pons.es. SKIN ABSORPTION: Asingle prolonged exposure may result in the material being absorbed in harmful amounts. INGESTION: Single dose oral toxicity is low. The oral LD50 for rats is 2140-3990 mg/KG. Ingestion may cause gastrointestinal irritation or ulceration. Ingestion may cause burns of mouth and throat. INHALATION: May cause respiratory sensitization or asthma in susceptible individuals. Excessive exposure may cause irritation to upper respiratory tract. MSDS: JEFFCO 3102 PAGE 3 SYSTEMIC AND OTHER EFFECTS: Repeated excessive exposures may cause liver and kidney effects. Result if in vitro ("test tube") mutagenicity tests have been negative. 7. FIRST AID: EYES: Immediate and continuous irrigation with flowing water for at least 30 minutes is required. Promptly seek medical attention. SKIN: Immediately flush skin with plenty of water for at least 15 minutes while removing contaminated clothing, preferably under a safety shower. Seek medical attention immediately. Avoid prolonged or repeated contact to skin. Wash thoroughly after handling. INGESTION: Do not induce vomiting. Give large amounts of water or milk if available and transport to medical facility. INHALATION: Remove to fresh air if effects occurs. Consult a physician. NOTE TO PHYSICIAN: Corrosive. May cause stricture. If lavage is performed, suggest endotracheal and/or esophagoscopic control. If burn is present, treat as any thermal burn, after decontamination. No specific antidote. Supportive care. Treatment based on judgement of the physician in response to reactions of the patient. 8. HANDLING PRECAUTIONS: EXPOSURE GUIDELINE(S): None established. VENTILATION: Control airborne concentration below the exposure guideline. Use onfy with adequate ventilation. Local exhaust ventilation may be necessary for some operations. RESPIRATORY PROTECTION: Atmospheric levels should be maintained below the exposure guideline. When respiratory protection is required for certain operations, use an approved air-purifying respirator. MSDS: JEFFCO 3102 PAGE 4 SKIN PROTECTION: Use protective clothing impervious to this material. Selection of specific items such as gloves, boots, apron or full-body suit will depend on operation. Safety shower should be located in immediate work area. Remove contaminated clothing immediately, wash skin area with soap and water, and launder clothing before reuse. Contaminiated leather items, such as shoes, belts and watchbands, should be removed and destroyed. EYE PROTECTION: Use chemical irritation, use a full-face respirator. immediate work area. goggles. If vapor exposure causes eye Eye wash fountain should be located in 9. ADDITIONAL INFORMATION SPECIAL PRECAUTIONS TO BE TAKEN IN HANDLING AND STORAGE: Ground all transfer equipment. Hold bulk storage under a nitrogen blanket. This product should not come in contact with copper or copper-bearing alloys. Good general housekeeping procedure should be followed. 10. NFPA HAZARD RATING 4 = EXTREME 3 = HIGH 2 = MODERATE 1 = SLIGHT 0 = INSIGNIFICANT 11. REGULATORY INFORMATION HEALTH FIRE REACTIVITY SPECIFIC 3 1 0 STATUS ON SUBSTANCE LISTS: The concentrations shown in this document are maximum or ceiling levels (expressed in wight%, unless otherwise specified) to be used for regulations. Trade Secrets are indicated by "TS". FEDERAL EPA: COMPREHENSIVE ENVIRONMENTAL RESPONSE COMPENSATION and LIABILITY ACT of 1980 (CERCLA): N/A MSDS: JEFFCO 3102 SUPERFUND AMENDMENTS and REAUTHORIZATION ACT of 1986 (SARA} TITLE Ill: EPA HAZARD CLASSIFICATIONS: Acute Hazard yes Chronic Hazard yes Fire Hazard no N/A Pressure Hazard no Reactive Hazard no PAGE 5 Section 313 requires submission of annual reports of release of toxic chemicals that appear in 40 CFR 372 (for SARA 313). This information must be included in all MSDSs that are copied and distributed for this material. Components present in this product at level which could require reporting under the statue are: Phenol at a level < 15% If you are unsure if you must report more information, call the EPA Emergency Planning and Right-To-Know Hot Line: 800-535-0202 or 202-479-2449. TOXIC SUBSTANCES CONTROL ACT (TSCAl: The components of this product are contained on the chemical substance inventory list. OTHER REGULATORY INFORMATION: None known to this firm. The information herein is given in good faith, but no warranty expressed or implied is made. JEFFCO PRODUCTS urges suppliers and users of this product to evaluate its suitability and compliance with local regulations as JEFFCO PRODUCTS cannot forsee the nature of the final application nor final location of usage. DOT SHIPPING INFORMATION Not regulated NEICO AVIATION INC.2244 Airport Way, Redmond, OR 97756 (503) 923-2244 Fax 503-923-2255 Service Bulletin SB005-91 Subject: Shell DPL-862 resin, TETA curing agent Date: 4-9-91 (2 pages) First of all, please check to verify that your airframe kit is supplied with the above resin system. This system is considered superior in many respects to previous systems used. As with any system, there are always tradeoffs so please read and follow the following directions carefully regarding use of these materials. 1. Mix Ratio (BY WEIGHT) 14-18 parts TETA to 100 parts DPL-862 resin 2. You will note that the curing agent is very runny, almost water like in viscosity. While this makes for a very strong system since the resin is diluted very little, proper mixing does become much more important. WARNING: It will be your responsibility to thoroughly mix all batches of resin/curing agent and also to verify, on a regular basis, the accuracy of your ratio mix. If you are using an epoxy pump that has been calibrated for this ratio, it is still MANDATORY to check the ratio on a REGULAR basis. There are a multitude of factors that can adversely affect the ratio such as a clogged port or a seal that has an impurity stuck under it, etc. YOU MUST REGULARLY CHECK THE RATIO MIX AND VERIFY IT TO BE CORRECT. Failure to do so could result in improper or insufficient cure properties of the resin which in turn could result in bond failure. 3. Epoxy Pump Setup: When setting up your epoxy pump, it is very important to align the two dispensing spouts such that they will pour their respective fluids closely together in the mixing cup. To achieve this, bend the two spouts together such that the curing agent spout (smaller diameter and smaller container) is within 3/16" of the resin spout. This will allow the curing agent to land in the cup, essentially on top of the larger volume of resin and it greatly promotes a good mix. 4. To verify the accuracy of your pump, you'll need a very accurate ounce scale. Set the scale to zero out with you mixing cup on it (this is to zero out the "tare" weight). 5. Pump at least ten to 15 full strokes from the pumper into individual cups. 6. Weigh the resin cup and note the weight. 7. Multiply that weight by 0.18. This arrived at number is what the curing agent cup should weigh. Ratios as low as 14 per hundred are acceptable however the mixing then becomes even more critical. The ratio should be very accurate, however if it is off, correction must be made either to the pump itself (perhaps cleaning) or correct the ratio through noting the additional pumps required of which ever part requires increasing. 8. After pumping the desired amounts into your mixing cup, carefully stir the resin and "fold" in the curing agent with crossing stir movements. With a relatively low volume of curing agent, it is critical to stir the mixture very thoroughly. Do not allow any resin on the bottom or corners of the cup to not get fully mixed - this is the most common error in mixing. Mix thoroughly for at least two to four minutes before using or before mixing in any other materials such as micro or flax. 9. Be ready to apply the mixed resin immediately. While you do not have to work at a hectic pace, the resin will "kick" much more quickly when piled up thick in your cup. This is due to the "exotherm" characteristic of this and most resin systems. 8. Keep the lids secured on both resin and curing agent containers and do not heat excessively. Keeping the resin at a steady 72-78°F is ideal. This can be accomplished using a small watt light bulb placed in the pumper box. Typically a 25 watt bulb works well, but do check the temperature and adjust ifit gets too hot or too cold. 9. The curing time will vary greatly depending on ambient temperature and thickness of resin (ie: number of plies of BID tapes, amount of micro or flax mixed in, etc.). Generally, setting times will vary between one hour and 12 hours. Full cure at room temperature will require several days and an elevated temperature post cure is always recommended. At room temperature, for a relatively normal 3 BID layup, the resin should firm up within 4-6 hrs. A partial cup of resin will "exotherm" and "kick" often within 30 minutes thus it should not be left thick in a cup for long prior to use. At room temperature, the resin system will actually continue to gain strength for up to 30 days. 10. CAUTION While this resin system is by no means the most toxic, in fact it is less toxic than most systems used by kit suppliers, proper handling is critical to good health. The curing agent is typically the most toxic of the two elements and extreme care must be exercised to keep this agent off your skin. You should wear protective gloves and have adequate ventilation when ever using any resin system. Read and follow all printed warning / usage statements by the manufacturer. NOTE: Also read and follow the instructions supplied with by the pumper Manufacturer regarding the removal of air bubbles in the pumper system.