EZ~Spray - Smooth
Contents
1. Step 7 Do Not Stop Spraying until the material cartridge is empty or your project is finished e Move spray gun back and forth in a sweeping motion Apply plastic in thin layers Do not over spray in one position Step 8 Move spray gun to proper angles necessary to air deliver plastic into deep undercuts e Adjust output as needed while spraying While spraying you can adjust the volume of the plastic as necessary by varying plunger pressure control knob at the back of the gun Step 9 If Necessary Add Support Armature Once support the shell has attained adequate thickness a support armature wood electrical conduit etc can be quickly embedded in plastic For this mold two pieces of wood are embedded to provide level support during casting For more information about mold making techniques contact Smooth On at 610 252 5800 e After applying final layer check for holes and missed areas e Minimum finished shell thickness 1 4 0 64 cm of plastic Step 10 Let plastic cure for 1 hour at room temperature 72 F 23 C Section E Continued Spraying EZ Spray Plastic Steps 11 amp 12 Demold An adequate coating of mold release ensured easy separation of the plastic shell from the rubber mold Because the model was properly sealed and released the cured rubber mold is easily removed from the model surface The rubber mold reflects perfect detail captured from the original2. Casting Into The Mold Using EZ Spray Plastic Step 10 After excess plastic is trimmed away from the support shell perimeter using a grinder mold release is applied to the shell to release any spray plastic that might come in contact with it Step 11 The rubber mold is aligned and fits perfectly into the shell for casting Step 12 Because we want to paint the casting following demold a neutral auto body primer is sorayed into the mold cavity The primer will bond to the spray plastic providing a suitable base for painting Step 13 A cartridge of spray plastic is prepared and inserted into the spray gun as directed on page 3 Don t forget to insert flow restrictor before attaching static mixing tube The same sweeping application technique is used and in a matter of minutes the spray casting is finished It is allowed to cure one hour before being removed from the rubber mold Step 14 Demold Casting The finished casting reflects perfect detail captured from the original model by the spray rubber The casting is ready for painting The finished casting is less than 1 8 the weight of the original model Quantity of Spray Plastic Used To Make This Casting 0 60 of 1 Cartridge About 2 25 Ibs 1 02 kgs Section H Spraying StyroCoat Plastic This section gives you step by step instructions for coating foam using EZ Spray Styrocoat Plastic Before proceeding make sure that you have read the
3. use only Ease Release 2831 to release cured foam from the mold Do Not Use Silicone Based Release Agents Also cover all areas in the spray area that might come in contact with the spray foam Step 2 Follow directions for inserting a spray foam cartridge into the EZ Spray Jr Gun found on page 3 Don t forget to insert flow restrictor before attaching static mixing tube Step 3 Air Volume Control Lever is off Make sure air volume control lever is in the OFF position see picture at left pulled fully backward into an upright position Step 4 Material Output Aim spray nozzle down at inside wall of waste bucket and pull trigger to check product output Material flow from nozzle should be medium If the material flow from nozzle is too high or not high enough Step 4A Adjust the Plunger Pressure Control Knob to decrease or increase flow turn right to increase left to decrease Make sure you keep spraying while adjusting pressure Step 5 Adjust Air Volume Control Lever Push air volume control lever forward slowly until desired spray pattern is attained Too much air will result in atomization which is a waste of material 5A Material on bucket wall should be uniform in color Without taking your finger off the trigger go from bucket to rubber surface immediately e Do Not Add Too Much Air If you see a vapor cloud forming decrease air pressure by adjusting the Air Volume Control lever 17 Section I
4. Continued Spraying Foam Step 6 Spraying Foam Into a Rubber Mold Begin spraying foam onto mold surface at the bottom or base and move upward Foam expands and cures quickly Do Not Stop Spraying until the material cartridge is empty or your project is finished Other Application Tips e Move spray gun back and forth in a sweeping motion Apply foam in thin layers Do not over spray in one position e Move spray gun to proper angles necessary to air deliver foam into deep undercuts e Adjust output as needed while spraying While spraying you can adjust the volume of the foam as necessary by varying plunger pressure control knob at the back of the gun e After applying final layer check for holes and missed areas e Minimum finished casting thickness 1 4 1 2 0 63 cm 1 cm of foam Step 7 Let cure for 1 hour at room temperature 72 F 23 C before demolding You can then sand prime and paint Step 8 Cured casting is primed with auto body primer and painted with acrylic paints for a realistic finish Quantity of Foam Used To Make Casting 0 70 of 1 cartridge Weight of finished casting About 2 5 Ibs 1 13 kgs Section I Continued Spraying Flexible Foam EZ Spray FlexFoam is an expanding urethane foam 7 Ib density that can be used for a variety of special effects and industrial applications It gels quickly and holds a vertical surface curing to a strong
5. additional layers to give the mold strength and dimensional stability e After applying final layer check for holes and missed areas Step 9 Let silicone cure for 1 hour at room temperature 72 F 23 C e Minimum finished mold thickness 3 8 0 95 cm of rubber Quantity of Material Used Just over 1 5 cartridges of EZ Spray Silicone About 6 Ibs 2 72 kgs Step 10 Trim excess rubber from around perimeter This will help with registration of the support shell e Proceed To Section G Spraying A Plastic Support Shell For This Silicone Mold Ya Section G Spraying EZ Spray Plastic Over Silicone This section gives you step by step instructions for spraying EZ Spray Plastic to make a support shell mother mold over silicone rubber Before proceeding make sure that you have read the following parts of this manual Section A Equipment Overview Section B Getting To Know The Spray Gun and Section C Preparing To Spray EZ Spray Plastic has been re formulated to be more impact resistant and shrink less than the original formulation Read the EZ Spray Plastic technical bulletin before proceeding Safety First The spray area should be well ventilated Anyone in the spray area should wear personal protective equipment including the following Safety Glasses Step 1 Ease Release 200 is applied to all surfaces that may come in contact with spray plastic Use only as directed Step 2 Follow
6. directions for inserting a spray plastic cartridge into the EZ Spray Jr Gun found on page 3 Don t forget to insert flow restrictor before attaching static mixing tube Step 3 Air Volume Control Lever is off Make sure air volume control lever is in the OFF position see picture at right pulled fully backward into an upright position Step 4 Material Output Aim spray nozzle down at inside wall of waste bucket and pull trigger to check product output Material flow from nozzle should be medium If the material flow from nozzle is too high or not high enough Step 4A Adjust the Plunger Pressure Control Knob to decrease or increase flow turn right to increase left to decrease Make sure you keep spraying while adjusting pressure Step 5 Adjust Air Volume Control Lever Push air volume control lever forward slowly until desired spray pattern is attained Too much air will result in atomization which is a waste of material 5A Material on bucket wall should be uniform in color Without taking your finger off the trigger go from bucket to rubber surface immediately e Do Not Add Too Much Air If you see a vapor cloud forming decrease air pressure by adjusting the Air Volume Control lever 12 Section G Continued Spraying Plastic Over Silicone Step 6 Spraying Plastic Onto Rubber Mold Surface Begin spraying plastic onto mold surface at the bottom or base and move upward e Do Not Stop Spraying
7. thickness Minimum 3 8 1 cm e Adjust output as needed while spraying While Spraying you can adjust the volume of rubber by varying the control knob on back of the gun Step 6 Use a brush to work drips back into the mold You can use a gloved hand or scraper to fill holes Step 7 Scrape excess off from model perimeter and leave a clean edge This will help align the sprayed support shell with the rubber mold Step 8 Let Cure 16 Hours At Room Temperature After the final layer is applied 72 F 23 C e Minimum finished mold thickness 3 8 0 95 cm How Much Rubber Was Used To Make This Mold 3 Cartridges of EZ Spray 45 mold rubber About 10 75 Ibs 4 87 kgs Section E Spraying EZ Spray Plastic This section gives you step by step instructions for spraying EZ Spray Plastic to make a support shell mother mold over urethane rubber Before proceeding make sure that you have read the following parts of this manual Section A Equipment Overview Section B Getting To Know The Spray Gun and Section C Preparing To Spray EZ Spray Plastic has been re formulated to be more impact resistant and shrink less than the original formulation Read the EZ Spray Plastic technical bulletin before proceeding Safety First The spray area should be well ventilated Anyone in the spray area should wear personal protective equipment including the following Step 1 Apply Ease Release 200 to rubber
8. until the material cartridge is empty or your project is finished Other Application Tips e Move spray gun back and forth in a sweeping motion Apply plastic in thin layers Do not over spray in one position e Move spray gun to proper angles necessary to air deliver plastic into deep undercuts e Adjust output as needed while spraying While spraying you can adjust the volume of the plastic as necessary by varying plunger pressure control knob at the back of the gun Step 7 If Necessary Add Support Armature Once support shell has attained adequate thickness a support armature wood electrical conduit etc can be quickly embedded in plastic For this mold two pieces of 2x4 are embedded to provide level support during casting For more information about mold making techniques contact Smooth On at 610 252 5800 e After applying final layer check for holes and missed areas e Minimum finished shell thickness 1 4 0 64 cm of plastic e Let cure for 1 hour at room temperature 72 F 23 C Step 8 Demold Because this is a silicone rubber mold the support shell does not stick to it and the rubber easily separates from the model surface Quantity of Spray Plastic Used To Make This Support Shell 1 Cartridge About 3 5 Ibs 1 58 kgs Section G Continued Spraying Plastic Over Silicone Step 9 Demold continued The rubber mold reflects perfect detail captured from the original model
9. yet flexible foam with a good surface skin Read the EZ Spray FlexFoam technical bulletin before proceeding e Follow Steps 1 5 of Section I Spraying EZ Spray Foam to prepare EZ Spray Jr Gun and FlexFoam cartridge Step 6 Spraying FlexFoam Into a Rubber Mold Begin spraying foam onto mold surface at the bottom or base and move upward Foam expands and cures quickly e Do Not Stop Spraying until the material cartridge is empty or your project is finished Other Application Tips e Move spray gun back and forth in a sweeping motion Apply foam in thin layers Do not over spray in one position e Move spray gun to proper angles necessary to air deliver foam into deep undercuts e Adjust output as needed while spraying While spraying you can adjust the volume of the foam as necessary by varying plunger pressure control knob at the back of the gun e After applying final layer check for holes and missed areas e Minimum finished casting thickness 1 4 1 2 0 63 cm 1 cm of foam Step 7 Let cure for 1 hour at room temperature 72 F 23 C before demolding Cured casting reflects perfect detail captured by the mold Step 8 Assembled pieces are painted with various layers to create realism Quantity of Foam Used To Make Casting 1 cartridge Weight of finished casting About 3 75 Ibs 1 7 kgs Ya Section J Disassembly amp Disposal Of Empty Cartridge This section provides instru
10. EZ Spray Equipment Manual amp Usage Guide mwa m eee SMOOTHON SINCE 1895 www smooth on com EZ Spray Jr is a versatile convenient and easy to use spray system for spraying the following EZ Spray materials Spray urethane or silicone rubber for making molds of any original model Spray urethane plastic to make fast strong mother molds or castings Spray Styrocoat plastic to coat foam for themeing amp special effects Spray rigid or flexible foam that is ideal for making fast lightweight castings or special effects EZ Spray Urethane Rubber For making sprayed rubber molds used to cast concrete plaster wax etc Surface preparation applying sealing agent release agent required EZ Spray Silicone Rubber For making fast sprayed rubber molds that have the best release properties for production casting of resins plaster etc Minimal surface preparation required EZ Spray Urethane Plastic For spraying over cured rubber molds to make fast support shells mother molds Plastic can also be sprayed into rubber molds to make fast lightweight castings StyroCoat Foam Coating Coat large areas of foam and other surfaces quickly with a plastic that is impact resistant Can then be sanded primed and painted Great for creating themed environments theater and movie special effects EZ Spray Foams Make lightweight castings create special effects or use for lig
11. EZ Spray Silicone rubber to make a fast rubber mold Before proceeding make sure that you have read the following parts of this manual Section A Equipment Overview Section B Getting To Know The Spray Gun and Section C Preparing To Spray Also read the EZ Spray Silicone technical bulletin EZ Spray Silicone is a platinum silicone that offers advantages over EZ Spray 45 urethane mold rubber 1 Silicone rubber cures quickly you can have a cured mold ready for casting in a few hours vs overnight with other mold rubbers 2 Because this is a silicone it does not stick to many surfaces surface preparation is minimal or not necessary Also a release agent is not necessary when casting into cured rubber molds 3 Cured rubber is soft strong and stretchy It will stand up to production casting of most materials including low temperature melt metal alloys Disadvantages 1 Platinum silicones are expensive vs other mold rubbers 2 Platinum silicones are more easily inhibited by contaminates on a model surface For example this silicone will not cure against modeling clays containing sulfur Read the EZ Spray Silicone technical bulletin before proceeding Safety First The spray area should be well ventilated Anyone in the spray area should wear personal protective equipment including the following e Important Use vinyl gloves only Do not use latex gloves with platinum silicones as cure inhibition may occur Step 1 Th
12. ck plastic component see picture at left that fits over the open end of a material cartridge The restrictor is required to prevent cross contamination of Parts A amp B in low viscosity spray materials like plastic or foam The restrictor also allows you to stop spraying saving material in a partially used cartridge for another time 2A Installing Flow Restrictor Place restrictor over the open manifold holes prior to attaching small static mixing tube Return to Step 3 above Preparing An EZ Spray Silicone Material Cartridge 1 Place material cartridge on a level surface and remove black retaining ring by turning counter clockwise This exposes the white manifold plug that prevents material leaks 2 Remove the manifold plug using pliers 3 Place a large static mixing tube over the open manifold Turn mixing tube clockwise and firmly hand tighten 4 Fit cartridge securely into gun 5 Attach air supply connector to the spray nozzle at the end of the static mixing tube Proceed to D Spraying Urethane Rubber Page 4 H Spraying Styrocoat Urethane Coating Page 15 E Spraying Support Shell Urethane Mold Page 6 I Spraying Foams Page 17 F Spraying Silicone Rubber Page 9 J Disposal Of Empty Cartridge Page 20 3 G Spraying Support Shell Silicone Mold Page 12 Section D Spraying EZ Spray Urethane Rubber This section gives you step by step instructions for spraying EZ Spray Urethane rubber Be
13. ction on removing an empty material cartridge from the EZ Spray Jr Gun This process shown below is identical for both the small and large static mixing tubes Step 1 Once a material cartridge has been fully dispensed it can be removed from the EZ Spray Jr Gun and discarded The first step is to disconnect the Spray Nozzle Air Supply Connector from the static mixing tube Begin by positioning your forefinger and middle finger under the red ring that locks the connector to the spray nozzle Step 2 Using your thumb for leverage pull back the red ring until it is flush with the Air Supply Connector This will unlock the connector from the spray nozzle Step 3 Without releasing the red ring pull the Air Supply Connector up and away from the spray nozzle Step 4 To remove the cartridge from the gun the dual cartridge plunger must first be fully retracted Set the Plunger Direction Control to the Reverse position Press and hold the trigger until the plungers are fully retracted Step 5 Lift the empty material cartridge out of the gun The cartridge static mixing tube and spray nozzle are fully disposable and can be discarded 20 imeroducing A New Addition lo The EZ Spray Lineup EZ Spray Silicone 20 Brings Versatility to a Complicated Mold Making Technique EZ Spray Silicone 20 cures in about 10 minutes i Wi with negligible shrinkage to a strong durable mold an f XN an Creating the per
14. e amount of air delivered to the spray nozzle 0 Spray Nozzle Air Supply Connector Attaches to end of static mixing tube combines air with rubber or plastic and sprays material 11 Spray Nozzle Air Supply Line Routes air from compressor quick connect to end of static mixing tube 12 Stabilizer Handle Helps hold the gun steady during use Attaching Air Pressure Regulator Connecting Gun to Air Compressor The air pressure regulator attaches to the gun at the base of the handle see right An air hose quick connect included is attached to the base of the regulator see above An air supply is connected to the gun Section C Preparing To Spray Step By Step Preparing An EZ Spray Urethane Rubber Plastic or Foam Material Cartridge ae i _l g 1 oa 1 Place material cartridge on a level surface and remove black retaining ring by turning counter clockwise This exposes the white manifold plug that prevents material leaks 2 Remove the manifold plug using pliers Spraying Plastic or Foam See Step 2A below 3 Place a small static mixing tube over the open manifold Turn black retaining ring clockwise and firmly hand tighten 4 Fit cartridge securely into gun 5 Attach air supply connector to the spray nozzle at the end of the static mixing tube Spraying EZ Spray Plastic Styrocoat or Foam Flow Restrictor REQUIRED A flow restrictor is a small bla
15. e original model used for this demonstration is made of plaster Apply Release Agent Silicone does not stick to most surfaces and is not necessary However silicone can mechanically lock on to many surfaces like dry plasters stone concrete etc Applying Ease Release 200 will aid in releasing the rubber from these surfaces Read the product technical bulletin for more information Step 2 Unique Static Mixing Tube amp Spray Nozzle Required EZ Spray Silicone is thick high viscosity A larger static mixing tube is required to successfully spray this silicone Make sure you have the correct static mixing tube then follow directions for inserting a spray silicone cartridge into the EZ Spray Jr Gun found on page 3 e Do not use the flow restrictor with this static mixing tube Step 3 Turn Air Volume Control Lever 1 4 turn toward the ON position until there is some air coming out of the spray nozzle see picture at left Section F Continued Spraying EZ Spray Silicone Step 4 Material Output Aim spray nozzle down at inside wall of waste bucket and pull trigger to check product output Material flow from nozzle should be medium If the material flow from nozzle is too high or not high enough Step 4A Adjust the Plunger Pressure Control Knob to decrease or increase flow turn right to increase left to decrease Step 5 Adjust Air Volume Control Lever Push air volume control lever forward slowly until des
16. fect rubber good for production casting of polyester B aad vacuum bag using epoxy or urethane resins gypsum concrete and p NA AN 4 EZ Spray Silicone 20 other materials a NMA E EZ Spray Silicone 20 is also effective at making fast cost effective vacuum bags for producing composite parts Newly sprayed or injected bags can be removed from the mold in 10 minutes and used immediately in production with polyester or epoxy resin systems The advantage that EZ Spray Silicone 20 offers vs conventional vacuum bagging systems is the speed at which a production ready silicone bags can be made resulting in significant time and labor savings Composite hood created by Vermont SportsCar Rallying www vtcar com For more information visit www smooth on com Smooth On Inc Copyright 2009 2000 Saint John Street Easton PA 18042 800 762 0744
17. following parts of this manual Section A Equipment Overview Section B Getting To Know The Spray Gun and Section C Preparing To Spray EZ Spray StyroCoat Plastic is a urethane plastic made for coating foam models used for creating special effects themed environments and other applications It gels quickly and holds a vertical surface curing with an impact resistant relatively smooth surface that can be sanded primed and painted Read the StyroCoat Plastic technical bulletin before proceeding Safety First The spray area should be well ventilated Anyone in the spray area should wear personal protective equipment including the following Step 1 StyroCoat urethane plastic will stick to almost any surface Cover all areas in the spray area that might come in contact with the spray plastic Step 2 Follow directions for inserting a StyroCoat cartridge into the EZ Spray Jr Gun found on page 3 Don t forget to insert flow restrictor before attaching static mixing tube Step 3 Air Volume Control Lever is off Make sure air volume control lever is in the OFF position see picture at left pulled fully backward into an upright position Step 4 Material Output Aim spray nozzle down at inside wall of waste bucket and pull trigger to check product output Material flow from nozzle should be medium If the material flow from nozzle is too high or not high enough Step 4A Adjust the Plunger Pressure Control Kn
18. fore proceeding make sure that you have read the following parts of this manual Section A Equipment Overview Section B Getting To Know The Spray Gun and Section C Preparing To Spray Also read the EZ Spray 45 Urethane technical bulletin Safety First me Gloves The spray area should be well ventilated Anyone in the spray area should wear personal protective equipment including the following The original model for this demonstration is a highly detailed relief made from gypsum SuperSeal Sealer Ease Release 200 Step 1 Seal amp Release Model The EZ Spray 45 technical bulletin will tell you that urethane rubber will bond to many surfaces To prevent sticking a sealing agent followed by a release agent must be applied to the model s surface before applying rubber For this model SuperSeal sealing agent followed by Ease Release 200 is applied e Follow directions for inserting a spray cartridge into the EZ Spray Jr Gun found on page 3 Step 2 Turn Air Volume Control Lever to the OFF position see picture at right pulled fully backward into an upright position Step 3 Adjust Material Output Aim spray nozzle down at inside wall of waste bucket and pull trigger to check product output Material flow from nozzle should be medium If the material flow from nozzle is too high or not high enough Step 3A Adjust the Plunger Pressure Control Knob to decrease or increase flow turn right to
19. htweight reinforcement EZ Spray Jr vs Commercially Available spray Machine What s The Advantage 1 Lower Cost In The Short Run No up front expense to buy a spray machine 25 000 Convenient amp Easier to Use i If you have a compressor you can spray rubber plastic or foam Time amp Labor Savings No Cleaning amp No Maintenance A Equipment Overview ccccccsccssccsssccssccssscsssccssscsssccescossceescoss 1 B Getting To Know The EZ Spray Jr Gun essssecssssceossscesssseesse 2 Ce Preparing TO SPAY sissessscsssscicessciecssciccscseccsesescsavececsssscadsensneseses 3 D Spraying EZ Spray Urethane Rubber sssscsssseosssseossssoossssse 4 E Spraying EZ Spray Plastic cccccccsscscccsssccccccsccccsscsccccees 6 F Spraying EZ Spray Silicone Rubber cccccssssscccsssscceeees 9 G Spraying EZ Spray Plastic Over Silicone cscscccccssssserseees 12 H Spraying Styrocoat Plastic cccccccsssccccssccccsscccccsscscesssssees 15 Spraying EZ Spray Foam i ccccccscccccsssccssccccssccccscccccsccsssces 17 J Disassembly amp Disposal Of Empty Cartridge c 00000 20 Before You Begin Think Have Necessary Materials On Hand Before You Start Includes spray rubber plastic and or foam adequate air supply static mixing tubes brushes disposable cleaning rags acetone for cleaning and 3 scraper Store Sp
20. increase left to decrease Make sure you do not stop dispensing material Step 4 Adjust Air Volume Control Lever Push air volume control lever forward slowly until desired spray pattern is attained Too much air will result in atomization which is a waste of material 4A Material on bucket wall should be uniform in color Without taking your finger off the trigger go from bucket to model surface immediately Section D Continued Spraying EZ Spray Urethane Step 5 Applying Mold Rubber To Model Surface Begin by spraying rubber onto model surface at the bottom or base of the model and move upward Apply rubber to underside and undercuts first e Do Not Stop Spraying until the material cartridge is empty or your project is finished Other Application Tips e Do not over spray in one position Rubber will pool and drip downward This may also entrap air which will be reflected in the finished mold e Apply an initial thin layer the initial layer should be thin so that air is not entrapped e Brush Material Have a helping pair of hands ready to brush material into detail and undercuts Make sure breathing protection is worn e Move spray gun to proper angles necessary to air deliver rubber into surface detail and deep undercuts e Apply additional layers After model is completely covered with a uniform 1st layer apply subsequent layers to give the mold strength and dimensional stability Ultimate mold
21. ired spray pattern is attained Too much air will result in atomization which is a waste of material 5A Material on bucket wall should be uniform in color Without taking your finger off the trigger go from bucket to model surface immediately e Do Not Add Too Much Air Step 6 Applying Mold Rubber To Model Surface Begin spraying rubber onto model surface using a sweeping back and forth motion Step 6A Brush Material Have a helping pair of hands ready to brush material into detail and undercuts Make sure breathing protection is worn by anyone in the spray area e Do Not Stop Spraying until the material cartridge is empty or your project is finished Other Application Tips e Apply an initial thin layer the initial layer should be thin so that air is not entrapped e Do not over spray in one position This will cause rubber to pool and drip downward This will also entrap air which will be reflected in the finished mold and subsequent castings e Move spray gun to proper angles necessary to air deliver rubber into surface detail and deep undercuts 11 Section F Continued Spraying EZ Spray Silicone Step 7 Adjust output as needed while spraying While spraying you can adjust the volume of rubber as necessary by varying plunger pressure control knob at the back of the gun Step 8 Apply additional layers After model is completely covered with a thin and uniform first layer apply three
22. model Step 13 The support shell is supported by the encapsulated wood strips to provide a stable level surface for casting The rubber mold is aligned and fits perfectly into the shell Quantity of Spray Plastic Used To Make This Support Shell 2 Cartridges About 7 1 Ibs 3 2 kgs Casting Into The Mold Using EZ Spray Plastic e Because this is a urethane mold Ease Release 200 release agent is applied as directed into the mold cavity Step 14 Because we want to paint the casting following demold a neutral auto body primer is sprayed into the mold cavity The primer will bond to the spray plastic providing a suitable base for painting e A cartridge of EZ Spray Plastic is prepared and inserted into the spray gun as directed on page 3 Steps 15 amp 16 The same sweeping application technique is used and in a matter of minutes the spray casting is finished It is allowed to cure one hour before being removed from the rubber mold Steps 17 amp 18 A faux stone finish spray paint is applied to give the finished casting a textured look The finished casting reflects perfect detail captured from the original model by the spray rubber The finished casting is less than 1 8 the weight of the original model Quantity of Spray Plastic Used To Make This Casting 1 Cartridge About 3 6 Ibs 1 63 kgs Section F Spraying EZ Spray Silicone Rubber This section gives you step by step instructions for spraying
23. mold surface and all surrounding surfaces that may come in contact with spray plastic Use only as directed Step 2 Follow directions for inserting a spray plastic cartridge into the EZ Spray Jr Gun found on page 3 Don t forget to insert flow restrictor before attaching static mixing tube Step 3 Turn Air Volume Control Lever to the OFF position see picture at right pulled fully backward into an upright position Step 4 Adjust Material Output Aim spray nozzle down at inside wall of waste bucket and pull trigger to check product output Material flow from nozzle should be medium If the material flow from nozzle is too high or not high enough Step 4A Adjust the Plunger Pressure Control Knob to decrease or increase flow turn right to increase left to decrease Step 5 Adjust Air Volume Control Lever Push air volume control lever forward slowly until desired spray pattern is attained Too much air will result in atomization which is a waste of material 5A Material on bucket wall should be uniform in color Without taking your finger off the trigger go from bucket to rubber surface immediately e Do Not Add Too Much Air If you see a vapor cloud forming decrease air pressure by adjusting the Air Volume Control lever Section E Continued Spraying EZ Spray Plastic Step 6 Spraying Plastic Onto Rubber Mold Surface Begin spraying plastic onto mold surface at the bottom or base and move upward
24. ob to decrease or increase flow turn right to increase left to decrease Make sure you keep spraying while adjusting pressure Step 5 Adjust Air Volume Control Lever Push air volume control lever forward slowly until desired spray pattern is attained Too much air will result in atomization which is a waste of material 5A Material on bucket wall should be uniform in color Without taking your finger off the trigger go from bucket to rubber surface immediately e Do Not Add Too Much Air If you see a vapor cloud forming decrease air pressure by adjusting the Air Volume Control lever 15 Section H Continued Spraying StyroCoat Plastic Step 6 Spraying Plastic Onto Foam Model Begin spraying plastic onto model surface at the bottom or base and move upward e Do Not Stop Spraying until the material cartridge is empty or your project is finished Other Application Tips e Move spray gun back and forth in a sweeping motion Apply plastic in thin layers Do not over spray in one position e Move spray gun to proper angles necessary to air deliver plastic into deep undercuts e Adjust output as needed while spraying While spraying you can adjust the volume of the plastic as necessary by varying plunger pressure control knob at the back of the gun e After applying final layer check for holes and missed areas e Minimum finished coating thickness 1 4 0 64 cm of plastic Step 7 Let cure fo
25. r 1 hour at room temperature 72 F 23 C before Sanding priming and painting e This model measured 4 5 tall 2 25 sq ft at the top and 3 75 sq ft at the base Quantity of StyroCoat Used To Coat This Model 8 25 Cartridges About 31 Ibs 14 kgs Model used for this demonstration is part of the stage set for Elton John s latest Broadway play Dracula Courtesy Spoon Group in Rahway New Jersey Section I Spraying EZ Spray Foam This section gives you step by step instructions for spraying EZ Spray Foam Rigid amp FlexFoam into a rubber mold Before proceeding make sure that you have read the following parts of this manual Section A Equipment Overview Section B Getting To Know The Spray Gun and Section C Preparing To Spray EZ Spray Rigid Foam is an expanding urethane foam 8 Ib density made for creating lightweight foam castings special effects themed environments and other applications It gels quickly and holds a vertical surface curing with an impact resistant relatively smooth surface that can be sanded primed and painted Read the EZ Spray Rigid Foam technical bulletin before proceeding Safety First The spray area should be well ventilated Anyone in the spray area should wear personal protective equipment including the following Step 1 For this demonstration we will spray foam into a silicone rubber mold Apply Release Agent If spraying into a urethane rubber mold
26. ray Materials At Room Temperature 72 F 23 C Work Area Should Be Above 65 F 18 C Safety First e Work Space Should Be Well Ventilated e Personal Protective Equipment Anyone in spray area should wear safety equipment including gloves eye wear and a NIOSH approved respirator e No Smoking Do not smoke in the work area or in the presence of flammable solvents such as acetone Mandatory Safety glasses NIOSH approved respirator and rubber gloves Section A Equipment Overview What You Need NN This section will introduce you to the key components of the EZ Spray Jr Spray System and tell you what you need to have on hand before you begin Required Equipment 1 Air Compressor Minimum Compressor Rating 5 CFM at 90 PSI At least 5 Peak HP Minimum Operating Pressure 90 120 PSI Important Dry air is required to minimize the possibility of moisture contamination of sprayable urethanes A compressor dryer is recommended 2 The EZ Spray Jr Gun One time purchase available from your Smooth On distributor An easy to use spray gun that accommodates Smooth On s cartridges containing spray rubber plastic or foam Gun controls the delivery rate of material through the static mixer and air flow 3 EZ Spray Material Cartridges 4 Static Mixing Tubes Two Types Small Mixing Tube amp Nozzle Used with e EZ Spray 45 Urethane e EZ Spray Styrocoat e EZ Spray Plastic e EZ Spra
27. y Rigid Foam e EZ Spray Flexfoam Large Mixing Tube amp Nozzle Used with e EZ Spray Silicone 20 e EZ Spray Silicone 35 Rubber Plastic or Foam Part A and Part B packed in cartridges Squeezing gun trigger pumps equal amounts of material through manifold into static mixing tube 2 Plunger Air Cylinder 3 Plunger oe E Direction Control 12 Stabilizer Handle 5 Plunger Air Cylinder 4 Plunger Pressure Supply Line Control Knob 10 Spray Nozzle 6 Trigger Air Supply Pa Connector 11 Spray Nozzle Air J Supply Line 9 Air Volume Control Lever lt 7 Compressor Air Hose Connection lt 8 Air Pressure Regulator oh Dual Cartridge Plunger Forces A B material from cartridge through static mixing tube 2 Plunger Air Cylinder Pressurized air cylinder that initiates movement of plunger 3 Plunger Direction Control Withdraws cartridge plunger from empty cartridge when pressed simultaneously with trigger 4 Plunger Pressure Control Knob Controls volume of material dispensed by increasing or decreasing plunger air cylinder pressure 5 Plunger Air Cylinder Supply Line Delivers air to plunger air cylinder 6 Trigger Controls movement of cartridge plunger 7 Compressor Air Hose Connection Connects to your air compressor 8 Air Pressure Regulator Regulates the pressure from the air compressor into the gun 9 Air Volume Control Lever Regulates th
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