Joining the PanelsTo streamline the composite panel joining process, ATL Composites have developed the proprietary Z-Press. The press applies heat and pressure to cure the epoxy adhesive on the Z-Joints. Joins are fully cured in 7 to 20 minutes, depending on the ambient temperature, type of hardener, core type and thickness of the panel. Checking the "squeeze-out" on the joint until it has become rubbery, will indicate when you can proceed with the next join. Drums, or a purpose-built receiving stand, should be set up to support the full sized panel being joined. Once joined, the tabs can be cut to remove the full size parts of the DuFLEX kit. Large parts, for example a topside panel, may extend through two or more panels, so the panels should be joined before the tabs are cut. A mobile Z-Press for the composite panels is available for hire from ATL Composites and has an operation manual with details on care and operation of the unit.
Manual Edge Joining Instructions
Take two strips of 100mm wide, 19mm MDF (fibreboard) the length of the long side of the composite panel (2400mm). Cover one side of each strip with plastic packaging tape as shown. Drill pairs of 3mm (approx.) screw holes, 30mm each side of centre, through one strip at 100mm centres.
Apply a high-density epoxy adhesive to both Z-Joints, making sure there is adequate adhesive to cover all core and scarf joint areas, and push joints together with a maximum gap of 1mm.
Step 3 Lay the strip with no holes, plastic side up, underneath the glue joint; lay the holed strip, plastic side down, on top of the glue joint.
Step 4 Screw through the holed top strip into the bottom strip, ensuring faces are squeezed together firmly. Leave to cure overnight.
ATL Composites ONLY recommend the following high density adhesives for joining DuFLEX Z-Joints: Pro-Set® cartridge adhesive(available in the USA & Europe).
Applying Adhesive to the Z-Joint Prior to applying adhesive to the Z-Joint, carefully remove approximately 25mm of peelply from the outside edge of the male scarf with a Stanley knife, taking care not to damage the laminate. (Peel-ply has already been removed from the female scarf during machining at ATL). Scarfs should be brushed with a clean brush to remove dust and any contamination that would inhibit adhesion. It is important to apply enough high-density adhesive to cover both Z-joints and exposed core, and to allow adequate squeeze out when the joints are pushed together. The panels should be pushed together by sliding them back and forth to make a tight join of no more than 1mm, prior to applying pressure with the Z-Press or manual joining strips.
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