Do It Yourself Pilot CDI Build Up Instructions Continued By Bill Keefe

44. Now I take a good stiff knife and scrape the compound on the top. Don't over do it. I do this to 
remove the glaze and any remaining surface dirt. 



45. Top scraped. This also promotes adhesion of the new compound to the old. 
Blow away any scrapings. 



46. Now were going to cut the compound away from the bottom of the board so we can do the mod. 
I make one angle cut. Don't scrape the board. Ground yourself while working around exposed 
circuit boards to prevent possible damage from static electricity. 



47. Cut only deep enough so you don’t hit the board. Then pry the edge up and pull away the compound. 
Some boards are more difficult then others.



48. This is where we are going to do a solder joint. Take care to make sure this area is clear of all 
potting compound. 



49. Use 60/40 rosin core solder for this joint. Any brand is fine, but don't use anything but 60/40 solder. 



50. This is what the completed joint will look like. Make the solder joint as quickly as possible. 
Prolonged screwing around here puts excess heat into the board. 



51. This is where knowing how to solder will help. Check your work carefully when you are done. 
Clean the area. Wash hands ASAP. Solder is nasty toxic.



52. Time to get ready to pour. First thing: find or make a level table. I use a flat plate with jack screws.
 Makes quick work for getting level. I can't stress perfectly "LEVEL" enough here. All axis, all the way 
around. If it isn't level it will be more than obvious in the end result.  



53. Get out your new plastic case. Note the cellophane wrapper is flat on the bottom.



54. Leave the cellophane in place and wrap the side in masking tape. This will make clean up easy 
and keep any spilled compound from damaging the finish. Also, I always tape a piece of wax paper 
to the table so clean up is easy.  



55. OK get out your compound and get ready to mix it. Put your rubber gloves on. Stir the epoxy and 
then resin separately for about a minute each.  Stir very gently and slowly so not to whip any air into 
the fluid. This is an important step, so do this right, and use different stir sticks. 



56. Now pour all the black resin into a disposable cup. Make sure you scrape out the holding cup 
for all it is worth. Don't waste any.  



57. Write down what time it is. From mix time to pour time is 1/2 hour so make a note of what 
time you are going to pour. 



58. Pour the epoxy into the resin. Scrape clean like before. 



59. Stir mixture slowly and gently for about 2 minutes. Now we wait. 



60. 27 minutes later stir the mixture again for about a minute. The mixture is now ready to pour.  
Pour about this much into the case.



62. Roll the case around until it has flowed out to all the edges. Use a stir stick if needed. 



63. Coated all around the bottom and up the sides a little. 



64. Take the modified CDI unit and carefully slop some potting compound over the stripped area. 



65. Drop the CDI unit into the new case.



66. Begin pressing the CDI down into the new case. Not to fast. Try not to spill compound over the sides. 



67. Watch the sides as the compound starts flowing upward. It will even out and flow into dry areas 
after a few seconds. 



68. Once is has settled you need to put the top coat on. Pour some out and smear it around until 
the entire top is covered. 



69. You can use the stir stick to help flow. I'm pushing down here and towards the corner where the 
plug is. That is the most difficult corner to get filled. 



70. Plug corner fully filled. Looking good. 



71. Ready for a little touch up and drying. Check the box every hour or so. Carefully pop any bubbles
 that rise to the top within the first 5 hours.  



72. I allowed a little to flow over the edges. Excess compound I clean up with a knife edge. I just 
scrape the edge carefully until the overflow is gone. 


73. Set to dry now. It takes 24 hours for the compound to dry. Leave the to box set for 24 hours. 
Sometimes longer in cool or cold weather. 



74. Remove masking tape ASAP so it doesn't stick to or leave glue on the sides. 



75. Install o-rings.



76. Install the clips. Now your done. Go plug it in and make sure if it still works. 



77. Finished -  this is a brand new unit I did a while back. Bill..


Back to my Home page or to my discussion board to discuss any questions you might have.

PilotOdyssey.com by hoser..
Often Imitated But Never Duplicated Pilot Odyssey Web Page.




2005