Phase 4 — The Resin Pour
Phase 4: The Resin Pour (Direct Bond Method)
Status: Planned — may change based on actual experience. This phase has not been executed yet. The steps below are the planned approach and will be revised once the work is underway.
1. Scuff the Skin
Lightly sand the cured fiberglass skin (around the cells) with 120-grit paper and wipe with acetone. This ensures the new flood coat chemically bonds to the back skin.
2. The Seal Coat (Bubbles)
Mix ~16 oz of epoxy. Pour a thin skim coat over the fronts (blue side) of the solar cells. Use a brush to physically dab resin under the edges of the cells to push trapped air out. Wait for this to cure to a gel state (approx 3-4 hours).
3. The Flood Coat
Mix a large batch of epoxy (do not mix more than 32 oz at a time to prevent the bucket from overheating). Pour it into the frame over the front of the cells.
4. The Expansion Gap (CRITICAL)
Pour the resin until it is 1/16” below the top lip of the steel frame. Do not let the resin touch the top edge.
5. Torch the Bubbles
Lightly pass a torch over the surface to pop any remaining air bubbles. Keep the torch moving and away from the bus wires.
6. Cure
Let the panel sit perfectly level for 48 hours. The clay mound will prevent any resin from leaking out the bottom holes.
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