ProBox Install title

Installing ProBox with epoxy resins employs the same process as with a polyester installation, but there are some issues that need to be taken into consideration.

Polyurethane Foam: When installing into a polyurethane blank the process is identical to a polyester installation. The installation will be stronger due to the structural and adhesive properties of epoxy!

EPS (Expanded Polystyrene) Foam: The primary issue is with heat generated by the epoxy resin kicking off. This heat can be high enough to melt the EPS foam surrounding the box. We strongly recommended that a slow hardener be used to reduce the chance of heat buildup.

This heat buildup issue varies with different brands of epoxy resins so it is worth experimenting with the chosen brand before doing an installation to determine whether heat buildup is going to be a problem.

The effect of the heat on the EPS foam varies depending on the density of the foam. Typically, the higher densities have less melting issues than lower densities. Based on our experience any density below 2# requires extra care!

For situations where melting might be an issue, here are a number of suggestions for mitigating the problem.

1. DO NOT USE A FAST HARDENER! This is the main contributor towards creating excessive heat buildup. Only use a fast hardener if you have determined it does not create a heat buildup problem!

2. Consider installing a higher density material where the boxes will be installed. This material could be a higher density EPS or Polyurethane foam, or some other foam material that is not heat sensitive, such as, PVC foam. This block should be larger than the routed box cavity so that it protects the surrounding foam from any heat buildup. Balsa wood inserts can also be used very effectively.

3. Pour the resin into the cavity in several separate steps, this will minimize the heat buildup due to the lower volume of resin.

Cloth Reinforcement

4. Line the inside of the routed cavity with a layer of 6-oz cloth, as recommended on our reinforcement page. This layer of cloth will help insulate the foam from the heat.

5. Pre-coat the interior of the routed cavity with resin and allow it to kick before proceeding with the installation, this will help insulate the foam from the heat.

DO NOT use our die-cut covers with epoxy resin. Due to the chemical composition of the epoxy it will attack the adhesive backing on the covers, causing them to loosen and potentially leak! It is much better to use a heat tolerant masking tape to cover the top of the box and insert. One inch tape can easily be applied and then trimmed to fit the top. The screw holes can still be filled with clay without a problem.

If you have any concerns with an epoxy installation, don't hesitate to call us with any questions you might have!