Notes from Sandy's visit  3/24/99

Screws: 

• use a dab of epoxy on head of cap screws 
• use a dab of epoxy on threads of flat-head screws
• locktite is not space rated and should not be used on flight

• use RTV to bond wiring
• velcro can be used, but is probably more trouble than it is worth
• wires should be laced every two inches and bonded every inch (offset from the lacing)
• lacing knot is a clove hitch with two overhand knots on top
• anchor wire bundles with lacing wherever possible, such as to tray spacers
• don’t route wires around sharp corners; can put kapton tape or heat shrink on wires at corners to give added protection
• always leave service loops at ends of wires so that wires don’t pull tight
• can use kapton tape to spread wires across a flat surface to hold them in place, then bond with RTV

• all pins should be bonded with RTV
• the back of all connectors should be bonded with RTV
• RTV around each connector to plug hole in box
• epoxy all standoffs and box flat-head screws
• if concerned about the middle of long boards flexing, can build up RTV under the board and then press the board into the RTV; can also use plastic spacers
• be sure to use compressed air to blow out boxes well before assembly, then turn the box over and hit it on the table to jar anything loose out
• fill all connector holes with pins
• make sure to clean off excess heat sink compound that squeezes out from under boxes

• use kapton on the plate to keep the switch from shorting
• use epoxy to first fill the holes in the switch
• score switch plastic with x-acto knife
• epoxy switch directly to kapton
• RTV wire connectors

• RTV EEPROMS with a couple of dabs on the ends
• header pins should all be RTVed
• stagger connections on header pins
• anything in a socket should have a dab of RTV
• check on TNC settings battery to see if OK in space

• need hardware on big transistors with nut on top

• put kapton tape around sensor legs or fill in with RTV to prevent shorting
• line holes on launcher with kapton, then RTV sensor in
• bond standoffs
• can use teflon plastic washers

aux receiver:

• use dab of epoxy on coax connector
• RTV all short wires

• the thermal epoxy we have is OK for space – Deskin uses it as well
• check on spray foam from Lockheed instead of conformal coating
• use epoxy for plates
• RTV dries overnight and it dries with humidity – place it in a cabinet with bowls of water
• clean kapton with alcohol before bonding to it
• make sure to wipe everything down with alcohol before final assembly and then handle only with gloves
• mark each connector and each box with epoxy ink to show connections and orientation
• can use a toothpick to apply epoxy and then use q-tip to smooth it out to get a good seal

We have about 40 hours left with Sandy – she can bond wires and do all internal work on boxes.  She needs compressed air, lacing cord, 2 part epoxy, and both ends of everything labeled.