Epoxy went on the inner edges of the C-channels, and then the polyurethane foam was sprayed
down the inside of each. They were then forced in place over the aluminum backing and the
polycarbonate front. The extra thickness given by the epoxy made the fit extra tight, which
was good, as it helped insure a good seal. There's a lot of the stuff everywhere on the
cardboard, as some of it was testing of the foam's expansion, since I'd never used it
before. And some of it was just from setting the can down, after which the foam continued
to expand and squeeze its way out of the dispensing straw.
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There's another blurry picture, showing the negative therminal, and next to it, is a small
hole previously drilled out for the helium inlet. I decided that there was no good way
to keep the hole from being filled, so I just let it get filled over - I used the same
drill bit later on to just drill the foam out of the way, allowing for insertion of
the inflating needle.
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And an inside view of the negative terminal. The foam expanded very nicely, forcing its
way into every single space it could find, which was a really good thing, as it
should give an excellent seal. The corners of the panel didn't have any caps over them,
and the joints weren't cut perfectly to begin with, so the foam formed weird looking
"cysts" over the night. These were just cut off with a razor blade.
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