Make your own sealed units

submitted by aia_cd_derekG
derekgale@shaw.ca

e-mail the author

 

I have used the following procedure for manufacturing double sealed thermopane units for years with excellent
results. All of the supplies can be purchased from CRL.

What you will need:-
1) CRL Double seal spacer bar: part# 39107 (for 3/8" bar)
2) CRL Polyisobutylene primary seal (also known as Vistanex): part# 2132559
3) CRL Rhoder-Therm sealant (10oz tubes that fit a basic caulking gun): part# 542
4) CRL M.S.D. Molecular sieve dessicant (5lb can): part# msd5

Tip: When ordering spacer bar always ask for the corners that fit the bar you are ordering.
The minimum order for bars is 20 lengths: for every 20 bars I order 100 corners.

Optional: If you plan on doing many units I suggest an air-powered gun. I use part# wg61001 with a guide top #sgt38

Clean the glass spotless. I use an electric polisher and Sprayway glass cleaner. Do not use wax or furniture polish on the edge where the spacer bar touches the glass

I always seal the film inside the unit. I run a 1/4" lead line 1/2" in from the edge of the glass leaving 1/2" of clear glass all round. On the flip side I use 3/8" lead and offset the 1/4" lead by 1/8". This hides any voids if the spacer bar is not perfectly against the lead.

Using a suitable table, support the glass with blocks around the outside only. On larger panels the glass will bow in the center. do not block the center, let it bow because the second sheet will also bend and the result will be more uniform.

Cut the space bar 15/16" shorter than the glass. Fill the two longer pieces with dessicant and snap the bar together using the proper corners. Carefully apply Vistanex to one edge of the spacer bar while it is flat on the table.

Side view of spacer bar

You can place it right in the groove, or to the outside of the groove. I use the outside because there is less chance any can squeeze into the unit.

Lay the Vistanex side of the bar down on the glass beside the lead edge and press firmly all the way round.

Apply Vistanex to the top side of the spacer bar.

With compressed air, blow off any dust and have one last look for fingerprints or smudges. Then squarely place the other glass on top and press together all the way around. This completes the primary seal.

Fill the edge completely with the secondary sealant and allow to cure overnight.

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