Awl grip repair - System II. Surfaces with heavily crazed, cracked, broken, delaminated gelcoat, and raw laminating resin. 1. Thoroughly scrub with commercial detergent or powdered household cleanser. Then rinse with fresh water until a break-free rinse is obtained. Allow to dry. 2. Inspect heavily crazed areas or damaged areas for excessive flexing or structural damage. Make structural reinforcements and fiberglass repairs as needed. 3. Remove heavily crazed, broken and delaminated gelcoat or fiberglass laminate. 4. Thoroughly grind out damaged areas with a 36-60 grit disk. Heavy crazing must be completely removed. Grind raw resin areas with 36-60 grit sand paper. 5. Prime these repair areas with 545 Primer. Two or three coats may be needed. Allow to dry 12+ hours. OR: For heavily damaged areas and all areas where 36 grit paper was used, prime with HIGH BUILD Epoxy Primer. Reduce the first coat of HIGH BUILD Epoxy 25% by volume with T0006 Reducer. Two to three coats may be required. 6. Sand primed areas with 80 grit paper. 7. Blow off the surface with clean, dry compressed air while dry wiped with clean rags to remove sanding dust and residue. {Note: The repair areas are ready for fairing and surfacing. This will include application of some or all of the following products: HIGH BUILD Epoxy Primer ULTRA BUILD¨ Epoxy Primer Sprayable Fairing Compound AWL-FAIR¨ L.W. Trowelable Fairing Compound AWL-QUIK¨ Sanding Surfacer. Details of the application of these products are shown later.} After the fairing and surfacing is completed all areas of sound surface must be cleaned, sanded, and primed and prepped before applying a topcoat. ABOVE THE WATERLINE FAIRING & SURFACING Fairing and surfacing are similar activities with subtle but specific differences. Often both procedures will be used on the same project or surface. In general fairing involves the use of trowel applied filler putties such as AWL-FAIR¨ L.W., which can be applied to virtually infinite film thickness. Fairing often involves creating a new line or shape to the surface, not just filling low areas or dents and dings. Surfacing is usually accomplished through the use of liquid coatings which are relatively thick (viscous) products which will fill and cover scratches, dings, pinholes, light crazing, mold defects and other relatively minor physical defects on a surface or part which otherwise has a true or fair line. Awlgrip Corporation products which fit this description include ULTRA-BUILD¨, Sprayable Fairing Compound, High Build Epoxy Primer, and AWL-QUIK¨. Above the waterline fairing and surfacing has four basic requirements: Properly prepare and prime the surface with the recommended primer before starting any filling or fairing. Start work with heavy fillers and proceed to lighter products. Make large depressions or low spots into smaller or more shallow areas as your work progresses. Always sand between applications of AWL-FAIR¨ L.W. Always seal the completed fairing/surfacing system with at least two full wet coats of 545 Primer before topcoating. 545 Primer seals the relatively porous, heavily filled surfacing materials. This sealing also provides uniform color holdout for the AWLGRIP¨/AWLCRAFT¨ 2000 Topcoats, thus a better looking job with uniform gloss, color, and appearance. Warning: Do not use automotive body fillers, spot putties, lacquer glazing putties, or similar water sensitive products in fairing projects. These products are not designed for marine applications and will not adhere to AWL-FAIR¨ L.W. or Sprayable Fairing Compound. Fairing Procedures 1. Properly prepare and prime the surface. See surface preparation sections for each substrate for this information. It is recommended that two to three coats of HIGH BUILD EPOXY PRIMER be applied over the primer on metal surfaces and other projects which will require extensive amounts of fairing. The HIGH BUILD EPOXY PRIMER provides protection against sand throughs to the metal, plus after sanding it makes an excellent base on which to apply the AWL-FAIR¨ L.W 2. Examine the surface for highs and lows. Mark low areas with a pencil. Do not use felt tip markers or ink pens. 3. Sand areas where AWL-FAIR¨ L.W. is to be applied with 80 grit paper. For heavy fairing projects where the AWL-FAIR¨ L.W. will be applied to HIGH BUILD EPOXY PRIMER; sand the High Build with 60 to 80 grit paper. Blow off the surface with clean, dry compressed air while dry wiping with clean rags to remove sanding dust and residue. 4. Fill all areas deeper than 20 mils (500 microns) with AWL-FAIR¨ L.W. Fairing Compound. Thoroughly mix the material to a uniform pink color with no streaks or lumps. Warning: Do not add reducers, solvents or thinners of any kind to AWL-FAIR¨ L.W. See page 83 for AWL-FAIR¨ L.W. specifications. 5. Apply AWL-FAIR¨ L.W. by trowel to an area you can work in 15 to 20 minutes. Start with thin coats in low areas and build out to high areas. Allow to cure. Several applications may be necessary to fill large areas. Block and machine sand with 36 to 80 grit paper. Blow off sanding dust and residue before applying more AWL-FAIR¨ L.W. Stop when the faired surface has a uniform surface which meets the fairing quality specified for the project. SURFACING PROCEDURES Surfacing products in the Awlgrip line include AWL-QUIK¨ Sanding Surfacer, High Build Primer, ULTRA-BUILD¨ Primer, and Epoxy Sprayable Fairing Compound. Each product has unique characteristics which can help to make the surfacing process easier. A typical full fairing and surfacing project may use the following schedule of products. Some areas may need extra applications and additional block sanding to achieve specified quality (i.e. under dark hulls). Other areas of a project may use only a few, one, or none of the products in the schedule. It is not required that all listed products be used. It is required that all surfaces be properly prepared and sanded before applying the next product and no product be used beyond its recommended maximum dry film thickness. After initial priming or application of AWL-FAIR¨ L.W.: Sprayable Fairing Compound apply 2 to 3 coats. Allow at least 2 days (48 hours) to dry, then block sand with 60 to 100 grit paper. ULTRA-BUILD¨ or High Build Primer, apply 2 coats. Allow to cure overnight (12 to 24 hours). Block or machine sand with 80 to 120 grit paper. 545 Primer or AWL-QUIK¨ apply as necessary for spray or brush application to seal the fairing and surfacing products before topcoating. GUIDE TO SELECTING SURFACING PRODUCTS AWL-QUIK¨ (D8003/D9001) has twice the build per coat of 545 Primer. AWL-QUIK¨ dries fast, is easy to sand, and the easiest primer to brush. Can be used as both a sanding surfacer and as a finish primer in brush and roller applications. Will provide 2 to 3 mils of dry film. High Build Epoxy Primer (D8002 Off White Base/D9002 Yellow Base/ D3002 Converter) has twice the build per coat as AWL-QUIK¨. The yellow version is recommended for filling blast/grind profiles on metal surfaces. Cured product goes from medium-to-hard to sand after a few days of cure. Will provide 5 to 7 mils of dry film. Sanded High Build is an excellent base for AWL-FAIR¨ L.W. on major fairing projects. ULTRA-BUILD¨ (D8008/D3018) clean white color helps to start turning projects white. Can be applied to 15 to 20 mils dry film, double the fill of High Build per coat. ULTRA-BUILD¨ becomes very hard to sand after 48 to 96 hours of cure. Epoxy Sprayable Fairing Compound (D6001/D3011). Builds at twice the film thickness per coat of ULTRA-BUILD¨. Sprayable Fairing Compound often requires 2 to 3 days cure before it can be sanded. Easy to sand at extended cure. Mixed full body with no reducer, this product can be applied by trowel or knife to fill slight scratches or pinholes. Epoxy Sprayable Fairing Compound must be overcoated with either ULTRA-BUILD¨ or High Build before 545 Primer or AWL-QUIK¨ could be applied as a final primer. Only useEpoxy Sprayable Fairing Compound Compound for surfacing full panels. Do not use Epoxy Sprayable Fairing Compound when spot repairing. Tight time constrictions in spot repair schedules usually do not allow enough time for proper cure of the D6001/D3011. Use High Build or ULTRA-BUILD¨ on spot repair projects. FINAL PRIMING & TOPCOATING The final primer and application of the topcoat completes the coating system. Primers and Sealers: The final primer supplies a hard, tight film on which to apply the topcoat, sealing the more porous fairing or surfacing materials below it. This hard tight film supports the AWLGRIP¨ or AWLCRAFT¨ 2000 Topcoat maximizing the gloss and distinction of image (D.O.I.). For spray applications, 545 Primer is the recommended product for final priming and sealing. AWL-QUIK¨ is acceptable for use in brush and roll applications. When painting fiberglass/gelcoat, wood, and smooth surfaced aluminum (masts, spars, etc.), there are many projects where no fairing or surfacing materials are used. In these cases the initial priming of the surface and the final priming can all be part of the same process. The only real distinction is which coat of primer is being applied. Topcoats: The AWLGRIP¨ Premium Urethane Topcoat is a polyester based polyurethane coating which can be applied by spray, brush, roller or the roller/brush combination. Regardless of application method it provides the toughest finish available to the pleasure craft industry. AWLCRAFT¨ 2000 is an acrylic based polyurethane coating designed only for spray application. It is designed for the yard, applicator, or owner who is willing to sacrifice a little durability to have a faster curing, more easily repaired finish. A few points which apply to both the traditional AWLGRIP¨ finish and AWLCRAFT¨ 2000. Both products provide a tough, chemical, and abrasion resistant coating which has been proven to perform in the marine environment. Both products require two coats minimum--regardless of application technique. Some applicators prefer to use three coats, and three coats may be the easier way to go with some colors, but two coats minimum are needed to obtain proper performance. Do not clear coat over whites or pastels with either system. Each system has a clear available. For AWLGRIP¨ it is G3005 High Gloss Clear; for AWLCRAFT¨ 2000 it is F3029. However, these products should only be used over dark colors. Application of Final Primer 1. Sand the surface smooth with 120-220 grit paper. Grit choice will be determined by condition and make up of the surface. 2. Blow off the surface with clean, dry, compressed air while dry wiping with clean rags to remove sanding dust and residue. Then wipe with AWL-PREP¨ T0008 using the Two Cloth Method. 3. Tack off the surface with AWLGRIP¨ Tack Rags #73009. Spray Application 4. Apply two to three coats of 545 Primer. Allow at least one hour between coats. Allow the surface to dry 12 to 24 hours. Brush/Roll Application Apply two coats of 545 Primer or two coats of AWL-QUIK¨ Sanding Surfacer. Allow 12 to 24 hours between coats. Sanding between coats with 220-280 grit paper will give a smoother finish. Note: AWL-QUIK¨ is easier to apply by brush/roll than 545 Primer. However, 545 Primer will provide a more durable system. 5. Sand the entire primed surface with 220-400 grit paper to a smooth, flat finish. Blow off the surface with clean, dry, compressed air while dry wiping to remove sanding dust and residue. 6. Solvent wipe with AWL-PREP¨ using the Two Cloth Method. Repeat process as necessary until the surface is completely clean. Allow the surface to dry. 7. Tack off the surface with AWLGRIP¨ Tack Rags. Finish Coat Application Spray Application - AWLGRIP¨ Mix equal parts by volume AWLGRIP¨ Color Base and AWL-CAT¨ #2 Spray Converter. Reduce 25% with the appropriate reducer for the application conditions. Spray Application - AWLCRAFT¨ 2000 Mix two parts by volume AWLCRAFT¨ 2000 Color Base with one part AWL-CAT¨ #2 Spray Converter. Reduce 25% with the appropriate reducer for the application conditions. Using recommended spray equipment, apply a light, smooth, slightly wet tack coat to the surface. Allow tack coat to “flash off” 30 to 45 minutes. Then apply a full, wet coverage coat to achieve color coverage (i.e., hide) and film thickness requirements. If preferred, three coats may be used. Allow the second coat to “flash off” 30 to 45 minutes until only slightly tacky before applying third coat. Topcoating cannot be done in one coat. Brush/Roll Mix AWLGRIP¨ Color Base with AWL-CAT¨ #3 Brushing Converter. Reduce 25% to 35% with Brushing Reducer. Apply AWLGRIP¨ Topcoat in two coats* of 1.5 to 2.5 mils WFT each. Allow 12 to 14 hours between each coat. *Depending on film thickness applied and color choice, one or possibly two additional coats may be needed. Topcoating cannot be done in one coat. Sanding between coats with 280-400 grit paper will provide a smoother finish. After sanding, blow off sanding dust and residue while dry wiping. Solvent wipe with AWL-PREP¨ using the Two Cloth Method. Tack off the surface with AWLGRIP¨ Tack Rags. On large surfaces such as hull sides, transoms, and house sides, first roll the AWLGRIP¨ Topcoat and then smooth the roller stipple by lightly tipping the surface with a brush. This can be done with 2 painters working side by side (i.e., 1 rolling and 1 tipping), or with 1 painter rolling approximately 6 square feet and then tipping that area before rolling any further.