Tuesday, March 27, 2012

Two Part Epoxy and the Art of Roadside Repairs

Most roadside adventures involve tires.  Simple flats.  Sling a tread.  There was even the time when the wheel came off the van and passed dad before the back end settled down on the pavement.
I've done various roadside repairs.  Alternators, water pumps, hoses, ignition wiring, fuel pump, serpentine belts, fan belts.  Dad and I even replaced a motor on the side of the highway using a fencepost and the dashboard for a engine hoist.
On my way up to my uncles funeral in north Georgia, I had a new one.  The gauges all looked good, but the engine started bucking like it does when it overheats.  I pulled off at the next exit, fortunately it was less than half a mile, and into a little ma and pop gas station.  I opened the hood and sure enough it was smokin' hot.  After half an hour, it was cool enough for me to open the radiator cap.  No water.  I went in and got some coolant and dumped it in and then a gallon and a half of water.  When I started the engine, it was hissing.  With only one ear, I have no directional hearing.  I couldn't tell where the sound was coming from.  Finally I spotted a little stream of water that I traced back to the bypass tube.  Two pin holes in the steel tubing - not the hose.  This is not good.
Checked my watch.  Only 8:45pm.  I can call dad.  Oh, wait ... no I can't.  On my own.
Drove down the hill to WalMart, and went looking for potential solutions. I started with hose clamps and rubber tubing.  Unfortunately, I couldn't find appropriate tubing and I wasn't willing to wait until morning for an auto parts store.
Next my mind turned to JB Weld because there is a long standing Freeman tradition that anything can be repaired with either duct tape or two part epoxy.  Didn't find JB, but did end up with LockTite's version.  Now, how to make it stick.  Bought some steel wool, a screw driver and pliers (along with the two part epoxy).
With much effort, contortion, cut knuckles and burned fingers, I finally removed enough hoses and bundles of wires to sort of more or less kind of reach the problem area.  I crammed some steel wool into the space and used the screwdriver to scrub the area.  I pried the wool out and inspected it and repeated the process about 6 or 8 times until it was as clean as I could get it.  But, it was still dripping water.  I needed a clean dry surface to bond to.
I found the hose leading to the tubing and tried to blow air though it so the water would not be in the tube.  After much effort (and the concern that if I did succeed in putting my mouth on the hose I would end up blowing hot water in my own face)  I finally decide I just couldn't reach it.  Okay, on a search for a potential solution.
I scoured the interior of the car and the trunk.  I finally settled on a fountain pen.  I gutted it and shoved it into the hose an blew on it.  It worked like a charm (ignore those first degree burns on the back of my hand.  it doesn't hurt nearly as bad as cuts on my knuckles).  Now the tube was no longer dripping, but I wasn't content with the condition of the tube's surface.  Was it clean enough for the epoxy to stick.  Besides, how was I going to get the two part epoxy into the small little alcove the tube was hiding in.
Back inside to search for solutions.  I settled on drinking straws, brake part cleaner and contact cleaner.
I sprayed brake parts cleaner on the tube several times and scoured it again with steel wool.  One more time with brake part cleaner and then to air dry.  Then I sprayed it with contact cleaner ( a non residue cleaner) just in case the brake part cleaner left a residue.  Now to mix.
I used the cardboard from the epoxy packaging and mixed a good portion of goo.  I scooped some up and in the straw and threaded it through the small space and slathered it on the now reasonably clean area.  Several times.  Let the waiting begin.  According to package instructions, two hours to drill, sixteen hours until full strength.
At this point, the funeral is only 11 hours away and I still have 3 hours to drive.  I give it two.  While waiting, I head back in to buy some water - just in case.
It is now a week and a half and 950 miles later and I still have all the water I bought in my trunk.
I thank God for two part epoxy and a dad that could fix anything.

3 comments:

  1. Invention, it must be humbly admitted, does not consist in creating out of void, but out of chaos.
    --Mary Shelly, Introduction to Frankenstein

    My Dad could fix anything in the house or yard, but motors always eluded him. I often wish I could call him when I am wondering where the wiring for this switch goes, or how to point up the mortar on the bricks out front...
    --Carrie

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  2. Just goes to show that any problem can be solved with a little ingenuity! Great post!

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