To have your suit repaired
for you, please visit OsSystems.com
These
instructions describe the basic processes for replacing seals
and repairing holes. With these few pointers, you can accomplish
your own professional quality repairs and save money. The most
important step is to use only PB-300 glue. PB-300
is designed specifically for gluing drysuits.
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Supplies Needed |
Well ventilated work area
(preferably devoid of birds,
cats, dogs, small children, etc.) |
PB-300 glue** |
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Infrared heat lamp |
Repair molds** |
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Soap and water solution |
Replacement seals** |
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Cloth rags (white, lint free) |
Rubber or plastic roller |
Rubber gloves, protective eye wear,
respirator
(all rated for working with MEK)
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Masking tape |
Methyl Ethyl Keytone (optional)
Read and heed all
warnings
on can!! |
Acid brushes |
(** items available from OS Systems)
Removal Of Old Seals
First,
using a standard soap and water solution, thoroughly clean and
dry the seal and the nylon around the area where the old seal is
glued. This will keep any silicone or contaminates from
interfering with the gluing of the new seal. Also clean and
dry the area of the new seal that is to be glued. You can
either remove the old seal entirely, or cut the old seal off at
the edge of the nylon, leaving a band of the old rubber still
glued to the nylon. Both will work fine. If you cut the old
seal off, be careful not to cut the nylon. You will be gluing
the new seal over the band of old rubber. Removing the whole
seal is easy. Simply soften the glue by the gradual
application of heat, or Methyl Ethyl Keytone (MEK), a solvent.
Either process will cause the glue to soften, and the old seal
can be peeled off carefully. Heat can be applied with an
infrared heat lamp or by a hair dryer. Be careful not to burn
your fingers. Do not use an open flame to apply heat. MEK
can be applied with an acid brush. Both MEK and the acid
brushes are usually available in local paint stores. Be
careful to only use the MEK as the instructions on its can
indicate. Do not bring the glue, or the MEK, near an open
flame, or near any sparks. Both are flammable and can cause
injury if not used properly.
Seal
Positioning
Insert the
O.S. repair mold in the sleeve of the drysuit, allowing
the mold to stick out about 3- 4 inches through the end.
Position the new seal over the end of the mold and on the sleeve
where it will be glued. Fold the edge of the new seal back up
the mold so that both the seal and the nylon areas to be glued
are exposed. Apply masking tape around the nylon sleeve just
below the gluing area, and on the new seal, behind the folded
back portion. This will keep excess glue from running down and
messing up your suit or the seal.
Surface/Seal Preparation
If the old
seal has been completely removed, you will be gluing the new
seal directly to the nylon of the drysuit. Do not remove the
base coat of old glue that is left on the nylon. Do remove any
large bumps left in the old glue by reapplying heat, or MEK,
until the glue softens, and then wiping with an acid brush.
Apply two thin coats of PB-300 over the old glue to
smooth out the surface of the gluing area. Allow each coat to
dry before applying the next coat. If you have left the band
of old rubber still attached to the nylon, you will be gluing
the new seal directly over the old seal. Lightly wipe the
surface of the old rubber with MEK, if available. Apply two
thin coats of PB-300 over the old seal, as described
above. The inside of the new seal needs to be prepared also.
Do not rough up the rubber. OS Longlife Latex seals are
specially treated to be glued, using OS Systems' PB-300
glue without being roughed up. Lightly wipe the surface to be
glued with MEK, if available. Apply two thin coats of PB-300
to the area to be glued, letting each coat dry before applying
the next coat.
Attachment
Apply one
thicker coat of PB-300 to the nylon. While the
PB-300 is tacky, roll the edge of the seal down over the
nylon sleeve, positioning the seal where it needs to sit. The
wet PB-300 will cause the dry and wet glues to bond
together. Use the roller to gently work out any bubbles or
wrinkles, making sure the seal fits smoothly on the sleeve. If
your seal is not placed perfectly, reapply heat and gently
adjust the position. The seal should remain on the mold for at
least 1/2 to 1 hour to allow the glue to set up. Once the glue
is dry, remove the mold and turn the sleeve inside out. Apply
a bead of PB-300 around the edge on the inside, where the
seal meets the nylon. Allow this to dry thoroughly. If you
move the drysuit before the PB-300 is dry, the glue could
stick to another part of the drysuit. Check the edges of the
seal by picking at them with your fingernails. If any area
comes up, reapply a small quantity of glue to the lifting area.
Excess glue can be wiped off with MEK. The neck seal is
applied flat. All other steps are the same.
Patching Fabric Holes
The same
basic procedure, with PB-300, is used to patch holes in
the fabric of your drysuit. All fabric holes are patched on
the inside, polyurethane to polyurethane. With MEK, clean the
polyurethane surface of both the inside of the drysuit, and the
patch. Apply several thin coats of PB-300 and press the
two polyurethane surfaces together. Apply a thin bead of glue
around the edges of the patch to avoid snagging.
Tips
and Warnings
MEK is a
very useful solvent. It can be used to remove any excess
PB-300, to thin the PB-300, to remove seals, to clean
all areas prior to, and after, gluing. Use only in accordance
to the instructions provided with purchase. PB-300
contains the solvent MEK. Both PB-300 and MEK need to
be handled correctly.
Use only in a well ventilated
work area. Wear protective rubber gloves, and eye wear. Do
not expose to open flames or sparks. Store in a cool, dry
place. Acute overexposure to fumes can cause drowsiness,
nausea, dizziness, and eventually systemic damage. Skin
contact overexposure can cause drying, cracking, and defatting.
Ingestion can cause cramps, loss of consciousness, and
systemic damage. First aid for excessive exposure to fumes is
fresh air and water. First aid for excessive exposure to skin
contact is washing with cool water. First aid for ingestion is
to keep still and call for medical help
DO NOT INDUCE VOMITING.
In all cases, contact medical doctors immediately.
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