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Date: Mon, 20 Jun 2011 11:52:40 -0400
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From: Brent Regan <brent@regandesigns.com>
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Subject: Re: Door Seal on the IV-P
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I neglected to mention the reason for using the same material as the 
door seal for the patch. As the door seal inflates it gets bigger. This 
causes stress in the adhesive between the seal and the patch. If the 
patch is a rigid material the stress will be concentrated along the 
perimeter of the patch. Put a piece of scotch tape on a balloon then 
inflate the balloon to see this effect. This stress concentration can 
lead to "peal".  Using a thin patch that is the same material as the 
seal reduces the stress concentration as the patch can now expand with 
the seal.

Regards
Brent Regan

<<<During construction a "helper" managed to stab my door seal with an 
Exacto knife. I fabricated a small round patch out of the rubber 
material  that was supplied in the kits as the mating surface for the 
seals. First I thinned the material on a belt sander to about a 
millimeter thick. I then punched out a round patch. I roughed the seal 
area with 220 grit to remove the release agent and scuff the surface. I 
then used RTV silicone to glue on the patch, holding it on with a piece 
of masking tape for ~24 hours. That was 16 years ago and the patch is 
still holding fine.>>>>