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Heavy Damage Removal Kit Finishing Procedures

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Our most complete, easy-to-use mechanical kit! Restores up to 100 square feet of acrylic. Use to remove crazing, severe scratches and haze from acrylic plastics. Will polish the surface back to optical clarity.


A. TOOLS REQUIRED

  • (1) Random Orbital Sander
  • (1) Angle Polisher, (Rated at approx. 2500 RPM), with 4.75 inch diameter.
  • (1) Compressed Air - 120 pounds per square inch.
  • (1) Spray bottle - approximately 10 ounce capacity. (For clean water).

B. LIST OF CONTENTS:

  • (5) 120 Grit Wet/Dry Sandpaper 5" Discs
  • (5) 220 Grit Wet/Dry Sandpaper 5" Discs
  • (5) 400 Grit Wet/Dry Sandpaper 5" Discs
  • (2) 1500 Micro-Mesh 5" Discs
  • (2) 2400 Micro-Mesh 5" Discs
  • (2) 3600 Micro-Mesh 5" Discs
  • (1) Back-Up Pad, 4.75 inch diameter
  • (1) TufBuf polishing pad
  • (1) White sponge pad
  • (8 ounce) Micro-Gloss
  • (8 ounce) Anti-Static Cream
  • (2) Flannel Cloths
  • (1) Kit Parts Reorder Form
  • (1) Instructions

C. PREPARING FOR THE BEST RESULTS:

1. To avoid scratching plastic surfaces, do not wear watches, rings, or bracelets. Long fingernails should be covered with gloves.

2. Always keep the work surface and restoral materials clean. Contamination can cause scratches.

3. Work with adequate light. Set a bright light on the side opposite your restoral side. For better viewing on non-transparent surfaces, place the light at an angle.

4. Read the restoral instructions carefully and review the kit contents before starting.

D. DETERMINE TYPE AND EXTENT OF DAMAGE AND STARTING POINT

1. Crazing - A series of very fine shiny lines, stars ,or haze when viewed at an angle in bright light. Crazing is below the surface and usually cannot be felt with the fingernail. Requires aggressive sanding to remove. Begin with 120 grit sandpaper.

2. Deep Scratches - Easily felt with fingertips. Begin with 220 grit sandpaper.

3. Minor Scratches - Readily detected with fingernail. Begin with 400 grit wet/dry sandpaper.

4. Hairline Scratches and Light Scuffs, Scratches, and Hazing - Begin with 1500 or 2400 Micro-Mesh.

5. Very Fine Scratches (usually caused by improper cleaning methods) - Use Micro-Gloss and a TufBuf polishing pad.

E. THE PROCESS:

1. Mask off with heavy duct tape. Wet the surface. All sanding is done wet. Use firm even pressure to control the sander. Start the sander after contact with the surface. Adjust the sander speed until controllable with 1 hand operation. Start with the 120 grit wet/dry sandpaper. Cover the entire surface of transparency with long, sweeping motions. At regular intervals, change the directions of sweep to perpendicular of the previous motion. The damage is removed when all that can be seen is the pattern left by the sandpaper. Check for remaining damage with a bright light. This is the most time consuming step in the process.

2. Change to the 220 grit wet/dry sandpaper. Repeat Step 1 to remove the 120 grit scratches. This should take 3-5 minutes per square foot. Check for deep sanding swirls with a light.

3. Change to the 400 grit wet/dry sandpaper and repeat Step 1 to remove the 220 grit scratches. This should take 3-5 minutes per square foot.

4. Spray the surface with water. Using the 1500 Micro-Mesh, cover the entire surface of the transparency with long, sweeping motions. At regular intervals, change the directions of sweep to perpendicular of the previous motion. The damage is removed when all that can be seen is the pattern left by the Micro-Mesh. This process should take approximately 3-5 minutes per square foot.

5. Change to 2400 Micro-Mesh and repeat to remove the 1500 scratches. Always be sure to keep the surface wet when working with the Micro-Mesh discs.

6. Change to 3600 Micro-Mesh and repeat the above process to remove the 2400 scratches.

7. Attach the TufBuf polishing pad to the right angle polisher. Wet the surface with water. Apply approximately 1 tablespoon of Micro-Gloss and buff for 2-4 minutes. Re-wet the surface and add more Micro-Gloss, if necessary.

8. Attach the white foam sponge pad and repeat Step 7. Rinse the surface off with water. Wipe clean with a dry flannel cloth. All fine scratches should be gone. If not, repeat the buffing process.

9. Apply Anti-Static Cream sparingly to the surface, using a clean, dry, flannel cloth. Polish surface by hand to remove the static charge that has built up during the process. Clean sponge, TufBuf, and flannel cloths with mild detergent and rinse for future use.

F. BENEFITS OF MAINTAINING TRANSPARENCIES:

Pilots and passengers alike need and appreciate the clear and undistorted view that a well maintained transparency provides. Comfort, enjoyment, but more importantly - SAFETY, are all requirements today! The smallest of scratches can lead to crazing. By keeping transparencies smooth and optically clear, through regular maintenance, crazing can be avoided.

06/01/02  -  Heavy Damage Removal Kit