Aegis 2000 User manual

Windshield Repair
System
Kit 2000
Instruction
CONTENTS
FOR CUSTOMER ASSISTANCE………………………………………………..……..Inside Front Cover
LIMITED WARRANTY INFORMATION………………………………………….…….Inside Front Cover
INTRODUCTION TO YOUR QUICKSILVER TECHNOLOGY™SYSTEM
Welcome to the System………………………………………………………...1
Learning the to Use AEGIS®Equipment.……………………………………..2
AEGIS®Training Seminar………………………………………………………2
Types of Windshield Breaks……………………………………………………3
General Repair Guidelines……………………………………………………..4
Your AEGIS®QuickSilver Technology™ Equipment………………………..6
How the AEGIS®QuickSilver Technology™ Repair System Works………11
MAKING REPAIRS
Repair Procedure………………………………………………………………..12
Preparing the Windshield………………………………………………………13
Which Resin to Use……………………………………………………………..13
Setting Up Your Repair Fixture………………………………………………...14
Preparing the Injection Chamber………………………………………………16
Primary Dry Vacuum Cycle…………………………………………………….17
Initial Pressure Cycle……………………………………………………………18
Secondary Vacuum Cycle………………………………………………………18
Final Pressure Cycle…………………………………………………………….19
Curing the Resin…………………………………………………………………19
Finishing the Repair Process…………………………………………………..20
SPECIAL TECHNIQUES
Drilling Techniques………………………………………………………………21
Pit Filling………………………………………………………………………….24
Repairing Cracks………………………………………………………………...25
Advanced Techniques for Difficult Breaks…………………………………….26
TROUBLESHOOTING GUIDE
Problems and Solutions………………………………………………………...28
MAINTENANCE
Maintenance Schedule………………………………………………………….34
Replacement Parts……………………………………………………………...36
Save These Instructions

By Phone:
US/Canada: 888.247.6000
International: 608.274.9254
By Internet:
Website: www.aegistools.com
e-mail: [email protected]m
By Fax: [phone]
By Mail:
Letters: PO Box 259688, Madison, WI 53725-9688 USA
Packages: 2810 Syene Road, Madison, WI 53713 USA
Please provide the following information when you contact us: model number, serial number
(if applicable), date of purchase, your complete mailing address including zip code, your day-
time telephone number including area code and a description of the problem.
FOR CUSTOMER ASSISTANCE
LIMITED WARRANTY
What Does This Warranty Cover? Products manufactured by Aegis Tools International®are expressly warranted
to be free from defects in material and workmanship.
How Long Does The Coverage Last? Items covered by this expressed warranty are covered for one year from
the date of delivery. Parts and products not manufactured by Aegis®are covered by the warranty of the original
manufacturer. For additional information concerning parts or products not manufactured by Aegis®, you may con-
tact Customer Service. Service work and repairs performed at Aegis®are warranted for six months from the date of
repair.
What Will Aegis Tools International®Do? Seller’s exclusive obligation under this warranty is to repair the defec-
tive item or replace it, at Aegis’®option, without charge, provided the defective item is returned no later than 30
days after the end of the applicable warranty period. Aegis®reserves the right to use new, reconditioned or used
parts in performing warranty work.
What Does This Warranty Not Cover? This warranty is non-transferable. This warranty is void if the item has
been repaired, damaged, or modified by anyone other than Aegis®or has been damaged as a result of vandalism,
acts of God, misuse or abuse. This warranty does not cover normal wear and tear or damage caused by shipment.
How Do You Get Service? In order to be eligible for service under this warranty you must call Aegis®Customer
Service at 888.247.6000 or 608.274.9254 to get a return authorization number. Return the complete product with a
copy of the original purchase receipt and return authorization number, freight pre-paid and insured to Aegis®. Ae-
gis®will pre-pay return freight on warranty service. Return authorization numbers expire 30 calendar days after
issue.
Your Rights Under State Law: This warranty gives you specific legal rights, and you may also have other rights
which vary from state to state. ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING IMPLIED
WARRANTIES OF MERCHANTIBILITY OF FITNESS FOR PARTICULAR PURPOSE ARE DISCLAIMED. IN NO
EVENT SHALL AEGIS TOOLS INTERNATIONAL®BE LIABLE FOR ANY INCIDENTAL, SPECIAL, OR CONSE-
QUENTIAL DAMAGES, INCLUDING LOSS OF PROFITS.
This statement supersedes all previously published expressed warranties.
LIMITED WARRANTY
What Does This Warranty Cover? Products manufactured by Aegis Tools International®are expressly warranted
to be free from defects in material and workmanship.
How Long Does The Coverage Last? Items covered by this expressed warranty are covered for one year from
the date of delivery. Parts and products not manufactured by Aegis®are covered by the warranty of the original
manufacturer. For additional information concerning parts or products not manufactured by Aegis®, you may con-
tact Customer Service. Service work and repairs performed at Aegis®are warranted for six months from the date of
repair.
What Will Aegis Tools International®Do? Seller’s exclusive obligation under this warranty is to repair the defec-
tive item or replace it, at Aegis’®option, without charge, provided the defective item is returned no later than 30
days after the end of the applicable warranty period. Aegis®reserves the right to use new, reconditioned or used
parts in performing warranty work.
What Does This Warranty Not Cover? This warranty is non-transferable. This warranty is void if the item has
been repaired, damaged, or modified by anyone other than Aegis®or has been damaged as a result of vandalism,
acts of God, misuse or abuse. This warranty does not cover normal wear and tear or damage caused by shipment.
How Do You Get Service? In order to be eligible for service under this warranty you must call Aegis®Customer
Service at 888.247.6000 or 608.274.9254 to get a return authorization number. Return the complete product with a
copy of the original purchase receipt and return authorization number, freight pre-paid and insured to Aegis®. Ae-
gis®will pre-pay return freight on warranty service. Return authorization numbers expire 30 calendar days after
issue.
Your Rights Under State Law: This warranty gives you specific legal rights, and you may also have other rights
which vary from state to state. ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING IMPLIED
WARRANTIES OF MERCHANTIBILITY OF FITNESS FOR PARTICULAR PURPOSE ARE DISCLAIMED. IN NO
EVENT SHALL AEGIS TOOLS INTERNATIONAL®BE LIABLE FOR ANY INCIDENTAL, SPECIAL, OR CONSE-
QUENTIAL DAMAGES, INCLUDING LOSS OF PROFITS.
This statement supersedes all previously published expressed warranties.
FOR CUSTOMER ASSISTANCE
QuickSilver Technology™ is a trademark of AEGIS Tools International®, Inc. The device is patented under
United States Patent 6,485,281 and United States Patent 6,663,371.

Welcome to AEGIS®
Congratulations on your purchase of AEGIS®windshield repair equip-
ment! Your AEGIS®windshield repair equipment was designed and
manufactured by auto glass professionals for use by professionals.
Please read these instructions thoroughly before attempting to repair a
customer’s windshield.
PLEASE REVIEW AND FOLLOW THESE INSTRUCTIONS BE-
FORE ATTEMPTING A REPAIR ON A CUSTOMER’S VEHICLE.
Before doing any actual customer repairs please: READ ALL
INSTRUCTIONS and practice. We recommend repairing at least 6 breaks before
working on a customer’s windshield. Remember to wear eye protection, gloves
and protective clothing to prevent exposure to adhesives.
Disclaimer: AEGIS Tools International®, Inc., its principals and suppliers are
not responsible for damages resulting from misuse of this equipment.
THE WINDSHIELD REPAIR PROFESSION
To be successful at windshield repair, you need professional equipment, experience using your equip-
ment and a good understanding of the best practices in the industry. In the United States, windshield
repair professionals have the benefit of a voluntary standard that outlines proper procedures and prac-
tices. The standard, known as the Repair of Laminated Automotive Glass Standard (ROLAGS), was
approved in 2007 by the American National Standard Institute (ANSI).
The ROLAGS standard was developed by the National Glass Association (NGA) and the National
Windshield Repair Association (NWRA), two trade organizations in the automotive glass and windshield
repair industries. You can review and download the standard at www.rolags.com.
The guidelines and instructions for AEGIS®Windshield Repair equipment are intended to be compliant
and consistent with the ROLAGS standard. Our manual is updated and printed as needed to ensure
that it reflects the ROLAGS standard at the time of purchase. Since revisions to ROLAGS may have
occurred since purchasing your kit, it is best to check the ROLAGS website or www.aegistools.com for
the most up-to-date information.
The NWRA also administers a program to certify repair technicians who demonstrate proficiency and
compliance with ROLAGS. Information on NWRA certification is contained in your kit.
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LEARNING TO USE AEGIS®EQUIPMENT
While operating AEGIS® Windshield Repair equipment is not difficult, practice is required to become proficient.
The more you practice, you will learn each break is unique, and certain techniques yield better results on some
breaks than others.
For best results, follow these steps:
Get a scrap windshield and make several breaks with an AEGIS®Hook Tool (TLS2526).
Let the breaks stabilize 24 hours.
Review this manual.
 Repair the breaks according to the “Making Repairs” instructions in this manual before working on a cus-
tomer’s windshield.
If problems or questions arise, see the “Troubleshooting Guide” in this manual. If you do not find the solution,
contact AEGIS®. Our technical support staff is available 8 am to 4 pm CST, Monday through Friday.
AEGIS®TRAINING SEMINAR
Most AEGIS®users are self-trained, but training is available for those who want it. AEGIS®offers a compli-
mentary, hands-on windshield repair training at our Madison, Wisconsin headquarters. In a one-day, compre-
hensive session, you will learn from our experts how to perform repairs and care for your equipment. You only
pay for your travel and related expenses. However, for a fee, an AEGIS®trainer can conduct a seminar at your
location. Please contact us directly for more information about AEGIS®training seminars.
WINDSHIELD REPAIR SCIENCE
The windshield repair process involves evacuating trapped air, moisture and debris from a break using a vac-
uum, then using pressure to fill the damaged area with adhesive. The process permanently prevents the dam-
age from spreading and greatly improves the appearance of the break.
About Laminated Glass
Laminated glass is used in windshields and some side windows (sidelites) because it holds together when
shattered. Laminated glass consists of a polyvinyl butyral (PVB) interlayer bonding two layers of glass (lites).
The PVB layer is also called the laminate.
To view a 5-minute video of how windshields are made, go to the following web address:
http://www.youtube.com/watch?v=fg3moEI9V5g&feature=channel_page
Only laminated glass can be repaired. Back windows (backlites) and most sidelites are made of tempered
glass. Tempered glass shatters into small pieces when broken and cannot be repaired.
You will be able to repair a break in the outer layer of glass as long as it does not penetrate the PVB. When a
break damages the PVB (causing a foggy or
cloudy appearance) or affects the inside layer of glass,
the windshield should be re- placed.
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Any type of break in a windshield is called damage. Damage
can occur from the impact of an object or from stress on a
windshield caused by twisting or improper installation. The lo-
cation where a windshield is struck by an object is called the
impact point. Stress damage typically does not have an iden-
tifiable impact point.
There are four common categories of breaks. Although no
two breaks are ever exactly the same, most breaks will fit into
one of these four categories.
BULL’S EYE BREAK
A bull’s eye break will have a small impact point and a circu-
lar air-gap surrounding it.
This type of break is generally quick and easy to repair. A
properly repaired bull’s eye break will leave only a slightly visi-
ble pit at the impact point where the surface of the glass was
damaged or missing.
STAR BREAK
A star break has cracks of varying lengths and widths radiat-
ing from a center impact point.
This type of break will spread very easily from temperature
changes or stress placed on the glass. The star break is a more
difficult break to repair. A properly repaired star break will leave
a skeleton outline of the cracks and a slightly visible pit at the
impact point where the surface of the glass was damaged or
missing.
CRACK
A crack is a single line of separation in the outer layer of
glass with a microscopic gap. A crack may extend from an im-
pact point and sometimes will not penetrate the outer surface of
the glass. A crack is a more difficult break to repair. Even a
properly repaired crack will remain visible from the head-on
view. Instructions for crack repair will be covered in the
“Special Techniques” section of this manual.
COMBINATION BREAK
A combination break includes two or more of the break types
described above. The most common type of break is a combi-
nation of a bull’s eye break and star break. Combination
breaks can be filled very effectively, although the repaired
break will remain more visible than a bull’s eye.
TYPES OF WINDSHIELD BREAKS
TYPES OF WINDSHIELD BREAKS
Star Break
Crack
Combination
Bull’s Eye
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GENERAL REPAIR GUIDELINES
With your AEGIS®windshield repair equipment, you will be able to repair most, but not all, windshield breaks.
It is important that you analyze each break before beginning the repair process. Although there are no laws
regulating windshield repair in most countries, some states and countries require vehicle inspections. In these
locations, inspectors may have the authority to reject a windshield if they consider it unsafe.
The break size, condition and location should all be considered when evaluating the repairability of a break.
LOCATION
The Driver’s Primary Viewing Area (DVPA) is an area on the windshield approximately 12 inches wide (or
30.5 cm), from the top to the bottom of the wiper sweep centered directly in front of the driver.
ROLAGS allows repairs to be done in the DPVA depending on the size of the break. Refer to the table below
for size limitations. More than one repair is allowed in the DPVA as long as they are not closer than 4 inches to
each other.
However, AEGIS®does not recommend repairing damage in the DPVA; AEGIS®has always recom-
mended replacement as the best option in these instances due to customer acceptance and to prevent any pos-
sible effects on vision, especially at night.
SIZE
There are recommended limits on the size and type of damage that should be repaired. While it is possible to
repair larger damage, the structural integrity of the repaired glass may suffer. In addition, larger repairs will show
more evidence of the original damage and may not meet your customer’s expectations. The time it will take to
complete the larger repair may also be a deciding factor. ROLAGS size limits are:
*AEGIS® recommends 1.5 inches/ 3.8 cm diameter, including all legs.
*AEGIS® does not recommend repairs in the DPVA.
***AEGIS® recommends 6 inches/ 15.2 cm.
NOTE: It is to your advantage to know the regulations pertaining to vehicle inspection and wind-
shield damage in your area.
Type of Break Size Limit
Bull’s eye/Half Moon 1”/ 2.5 cm in diameter
Star Break/Combination Break
Outside DPVA 2”/ 5 cm in diameter, including all legs*
Inside DPVA 1”/ 2.5 cm in diameter**
Cracks
Outside DPVA 14”/ 35.6 cm long***
Inside DPVA 1”/ 2.5 cm long**
Surface Pit
Outside DPVA 1/8”/ 3 mm diameter, 3/8”/ 1 cm depth
Inside DPVA 3/16”/ 5 mm diameter**
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CONDITION OF THE BREAK
Repairs should NOT be made in the following situations:
 The damage penetrates both the inner and outer lites;
 There are 3 or more long cracks extending from the impact point;
 The damage is on the laminate or has discolored the laminate;
 The damage is on the inner lite;
 The damage has contamination that cannot be removed;
 The damage is in an area where value-added features, such as rain sensors, may be affected;
 The pit depth is greater than 3/8 inch (1 cm);
 Edge crack touches more than one edge of the windshield, and
 Any stress crack
CUSTOMER EXPECTATIONS
Properly setting the customer’s expectations prior to a repair can be the most important step to insuring customer
satisfaction. Visual aids are helpful in showing the customer what the finished product will look like.
Review of Repairable Breaks
 Break is in the outside lite
 Laminate/PVB layer is intact
 Break is outside the Driver’s Primary Vision Area
 Break is less than 1.5 inches (4 cm) or less than 6 inch (15 cm) crack
 No local or state restrictions
 Customer understands repair results
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PARTS OF YOUR AEGIS®
QUICKSILVER TECHNOLOGY™ WINDSHIELD REPAIR SYSTEM
FIX4500 Repair Fixture
FIX4000 QuickSilver Technology™ Chamber
PMP4015 Gauged Vacuum Pump
HOS2000 Hose Assembly
MIR2000 Mirror
LMP3000 12-volt UV lamp w/ suction cups
LIQ2060 Single Shots, Extreme II - 25 PK
LIQ2070 Single Shots, Crack Fill - 25 PK
LIQ2080 Single Shots, Polymer II - 25 PK
LIQ3000 Alcohol, 125 mL (4.2 oz)
LIQ2000 Glycerin, 30 mL (1.0 oz)
LIQ2030 Pit Polish, 60 mL (2.0 oz)
FRM9412 Instructions
CAS2019 Carrying Case
Supply Box (SBX5001) contents:
HDW5412 Razor blades – 6 PK
HDW3000 Mylar squares – 100 PK
SBX2017 Insert Seals, 10 PK
SBX2019 O-Rings, Small, 12 PK
SBX2021 O-Rings, Large, 12 PK
SBX2018 Single Shot Filling Adaptor (4)
KIT 2000 Contents
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YOUR AEGIS® QUICKSILVER
Your AEGIS®QUICKSILVER TECHNOL-
OGY™ Windshield Repair System (KIT2000) in-
cludes everything you need to make top-quality
repairs. In order to follow along with this manual,
it is important that you are familiar with the names
and uses of each component included in your kit.
REPAIR FIXTURE (FIX4500)
The repair fixture is the heart of your AEGIS®sys-
tem. It is designed to attach securely and easily to
any windshield. By pumping the plunger, the suction
cup holds the repair fixture tightly against the wind-
shield. The fixture holds the chamber assembly. The
adjustment lever allows you to center the chamber
over the break. The adjustment screw changes the
angle of the chamber so that you can work on curved
areas of the windshield.
QUICKSILVER TECHNOLOGY™ CHAMBER (FIX4000)
The QUICKSILVER Technology™ Chamber is made
up of the outer chamber, injection chamber and piston.
On the side of the outer chamber is the quick connect
plug where the hose attaches. At the base of the outer
chamber is the reusable insert seal which creates the air-
tight seal around the break.
The injection chamber, which screws into the outer
chamber becomes a reservoir for the resin. The piston
and injection chamber are rotated throughout the repair
process to draw dry suction, force hydraulic pressure and
inject resin into the break.
HOSE ASSEMBLY (HOS2000)
Quick-connect sockets at each end link the hose to
the chamber and the gauged vacuum pump.
GAUGED VACUUM PUMP
Pull the handle in a pumping motion to draw the vac-
uum. Pump attaches to the hose assembly. Readings
will vary slightly due to altitude and barometric pressure.
YOUR AEGIS® QUICKSILVER
TECHNOLOGY™ EQUIPMENT
Your AEGIS®QUICKSILVER TECHNOL-
OGY™ Windshield Repair System (KIT2000) in-
cludes everything you need to make top-quality
repairs. In order to follow along with this manual,
it is important that you are familiar with the names
and uses of each component included in your kit.
REPAIR FIXTURE (FIX4500)
The repair fixture is the heart of your AEGIS®sys-
tem. It is designed to attach securely and easily to
any windshield. By pumping the plunger, the suction
cup holds the repair fixture tightly against the wind-
shield. The fixture holds the chamber assembly. The
adjustment lever allows you to center the chamber
over the break. The adjustment screw changes the
angle of the chamber so that you can work on curved
areas of the windshield.
QUICKSILVER TECHNOLOGY™ CHAMBER (FIX4000)
The QUICKSILVER Technology™ Chamber is made
up of the outer chamber, injection chamber and piston.
On the side of the outer chamber is the quick connect
plug where the hose attaches. At the base of the outer
chamber is the reusable insert seal which creates the air-
tight seal around the break.
The injection chamber, which screws into the outer
chamber becomes a reservoir for the resin. The piston
and injection chamber are rotated throughout the repair
process to draw dry suction, force hydraulic pressure and
inject resin into the break.
HOSE ASSEMBLY (HOS2000)
Quick-connect sockets at each end link the hose to
the chamber and the gauged vacuum pump.
GAUGED VACUUM PUMP
Pull the handle in a pumping motion to draw the vac-
uum. Pump attaches to the hose assembly. Readings
will vary slightly due to altitude and barometric pressure.
Repair Fixture and Chamber Assembly
Suction Cup
Piston knob
Suction Cup
Adjustment lever
Injection Chamber
Plunger
Outer Chamber
Hose Plug
Adjustment Screw
Insert Seal
Insert Seal
Hose Assembly
Gauged Pump
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Blue Knurled Nut
QuickSilver Technology ™
Injection Chamber and Piston
Piston
Cap
O-Rings
Injection Chamber
Piston Knob
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Inspection Mirror
INSPECTION MIRROR (MIR2000)
The inspection mirror helps you to monitor the repair proc-
ess without getting in and out of the car. You will be able to
look directly into the rear of the break from your work area at
the front of the windshield.
12-VOLT UV LAMP WITH SUCTION CUPS (LMP3000)
All AEGIS®resins cure with ultraviolet rays. The UV lamp
easily mounts to the windshield with 4 suction cups for hands-
free curing. The 10 ft. power cord plugs into the cigarette
lighter inside the vehicle for complete mobile operation. Cur-
ing time with the LMP3000 is usually 60-90 seconds. If you
are using a different UV lamp, curing times may vary. Uses
AEGIS®UV bulbs (LMP5000 or LMP5002).
SUPPLY BOX (SBX5001)
Your AEGIS®QuickSilver Technology™ Windshield Repair
System includes a supply box filled with razor blades, Mylar
squares, insert seals, large and small o-rings, and single shot
filling adaptors. All supplies can be replenished individually
by ordering directly from AEGIS®. Part numbers can be found
in the Parts List on page 36.
Supply Box with Contents
12-Volt UV Lamp with
Suction Cups
Wear Eye Protection when using UV
lamps, excessive exposure can cause
permanent eye damage.
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RESINS
There are three different resins included in your AEGIS®
QuickSilver Technology Windshield Repair System. All are ex-
clusive to AEGIS®repair systems, require Mylar squares for
curing, and harden (cure) under exposure to ultraviolet light.
Resin must be stored at room temperature and out of any light
source, especially sun light. All resins are non-yellowing and
cure optically clear.
AEGIS®POLYMER II (LIQ2080)
Polymer II is thicker and works best on bull’s eyes and half-
moon breaks without any radiant cracks.
AEGIS®CRACK FILL (LIQ2070)
Crack Fill is thinner and works well on all types of breaks. It
works extremely well on breaks with small tight cracks.
AEGIS®EXTREME II (LIQ2060)
EXTREME II is the thinnest of the resins and has excellent
flow properties allowing you to fill the most stubborn breaks.
For your safety, read all labels and MSDS
sheets included in your kit. Use AEGIS®
resins only in a well-ventilated area and avoid contact with
eyes and skin. If any AEGIS®resin gets in your eyes, flush
with clean water for 15 minutes and see a doctor immedi-
ately. If you swallow any AEGIS®resin, drink two glasses of
water and see a doctor immediately. If you get any AEGIS®
resin on your skin, wash well with soap and water.
DO NOT allow AEGIS®resins to come in
contact with vehicle paint. AEGIS®resins
will damage vehicle paint; always use a
protective cloth in the repair area. The AEGIS® Hood Cover
(HDW5532) and Fender Cover (HDW5523) are sold sepa-
rately for this use.
Polymer II Single Shot
Crack Fill Single Shot
Extreme II Single Shot
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ALCOHOL
Alcohol is used to clean resin from the repair system parts.
GLYCERIN
Glycerin is used to keep rubber suction cups in top-
condition. It softens and treats the rubber suction cup of the
repair fixture and the inspection mirror, maintaining pliability
and extending service life.
PIT POLISH
Pit Polish can be used with Pit Filler, Polymer II, Crack Fill,
and Extreme II resins to provide a clearer finish.
Pit Polish
Glycerine
Alcohol
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HOW THE QUICKSILVER TECHNOLOGY™
AEGIS®WINDSHIELD REPAIR SYSTEM WORKS
The cross-sectional diagrams below show how the QuickSilver Technology™ repair process works.
Step One: Primary Vacuum Step Two: Primary Pressure
Step Three: Secondary Vacuum Cycle Step Four: Final Pressure Cycle
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REPAIR PROCEDURE
ENVIRONMENTAL FACTORS
There are a number of environmental factors that will affect
the outcome of a repair. The most important factors are pres-
ence of moisture in the break, temperature of the glass, dirt in
the break, or direct sunlight. To guard against excessive direct
sunlight, use the optional AEGIS®Sun Screen – UV Blocker
(KIT1044). Put a protective cloth over the hood area below the
break or use an AEGIS®Hood Cover (HDW5532) Fender
Cover (HDW5523).
Moisture
Moisture in a break will often show up as a cloudy area at the
bottom of the break. If moisture is present, dry the break with
the Moisture Evaporator (TLS5000) before proceeding.
Temperature
The ideal glass temperature for doing a repair is between
40°F and 85°F (5°C to 30°C).
COOL THE GLASS:
Park car in shade and open windows.
Run air conditioning or defroster on cool.
WARM THE GLASS:
Park car in heated building
Run heater or defroster on warm.
Dirt
Dirt or loose glass in the pit area must be removed. Gently
flick it out with the tip of a razor blade or the optional AEGIS®
Carbide Probe (HDW5040).
IMPORTANT
Before performing repairs for customers, carefully read
this entire manual and practice repairs on a scrap wind-
shield to become familiar with the process.
AEGIS®Hood Cover
AEGIS® Sun Screen
Moisture Evaporator
Sudden change in glass temperature
may cause break to run.
Too much heat can run a break.
When heat is used, always allow wind-
shield to cool before continuing.
Eye protection is recommended for this
procedure.
Making Repairs
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Direct Sunlight
Direct sunlight or even cloudy skies can produce enough UV
light to cure the resin prematurely. Always do repairs in the
shade or cover the work area with a shop cloth or an
AEGIS®Sunscreen UV Blocker (KIT1044).
PREPARING THE WINDSHIELD
Clean the glass around the break using an alcohol-
based glass cleaner. To avoid contaminating the
break, spray the glass cleaner on a towel. DO NOT
spray the cleaner directly onto the glass.
Put a protective cloth over the hood below the break area or
use an AEGIS®Hood Cover (HDW5532) or Fender Cover
(HDW5523) .
Use a dampened towel to moisten the suction cup on the in-
spection mirror. Gently press the mirror on the inside of the
window centered behind the break.
Inspect the break for dirt or glass debris. Clean the impact
point with the corner of a razor blade or AEGIS®Carbide Probe
(HDW5040), if necessary.
WHICH RESIN TO USE?
The decision will be a matter of preference, as you become
familiar with the different properties of each resin. As a general
guide:
AEGIS®POLYMER II
Polymer II is thicker and works best on bull’s eyes and half-
moon breaks without any radiant cracks.
AEGIS®CRACK FILL
Crack Fill is thinner and works well on all types of breaks. It
works extremely well on breaks with small tight cracks.
AEGIS®EXTREME II
EXTREME II is the thinnest of the resins and has excellent
flow properties allowing you to fill the most stubborn breaks.
Remember:
 Any of the 3 resins can be used for any type
of break.
 Always keep equipment clean to avoid any
mixing of resins.
 ALWAYS KEEP RESIN OUT OF
SUNLIGHT!
For your safety, read all labels
and MSDS sheets included in
your kit. Use AEGIS®resins only
in a well-ventilated area and
avoid contact with eyes and
skin. If any AEGIS®resin gets in
your eyes, flush with clean wa-
ter for 15 minutes and see a
doctor immediately. If you swal-
low any AEGIS®resin, drink two
glasses of water and see a doc-
tor immediately. If you get any
AEGIS®resin on your skin, wash
well with soap and water.
AEGIS®resin will damage
painted surfaces. DO NOT allow
resin to come into contact with
vehicle paint. See
“Troubleshooting” section if
spillage occurs.
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Hose Plug
Hose Plug in 12 O’clock Position
Blue Knurled Nut
Blue Knurled Nut in Highest Position
SETTING UP YOUR REPAIR FIXTURE
PARTS OF THE FIXTURE
The unique design of the QuickSilver Tech-
nology™ repair fixture allows repairs on virtu-
ally all windshield angles and curvatures. The
suction cup at the base of the fixture attaches
to the glass by pumping the plunger. The
plunger’s red line indicates if there is a loss of
suction. The opening in the fixture arm holds
the outer chamber. By releasing the adjust-
ment lever, the fixture opening can be posi-
tioned easily and precisely over breaks, and
can even reach into corners and near the
edges of windshields. Small angle adjust-
ments are made using the adjustment screw.
PREPARE THE INSERT SEAL
The insert seal must be clean and dry. Be sure there is no con-
tamination or build up of resin on the insert seal. If there is, clean
and dry it thoroughly before using or replace it.
SET UP THE FIXTURE
1. Insert Outer Chamber
a. Rotate blue knurled nut to its highest position on the
outer chamber.
b. Insert outer chamber into the arm, making sure the hose
plug is in 12 o’clock position.
c. Rotate outer chamber clockwise 5 full turns. The hose
plug should be in 12 o’clock position when finished with
rotations.
2. Attach the Fixture
a. Place the repair fixture on windshield and center the
break by looking through the outer chamber. Make sure
the impact point is visible in the opening of the bottom of
the outer chamber.
b. Push on fixture, then pump the plunger until the red line
is no longer visible.
Repair Fixture
knob
Piston
Suction Cup
Adjustment Lever
Injection Chamber
Plunger
Outer Chamber
Blue Knurled Nut
Hose Plug
Adjustment Screw
Insert Seal
Insert Seal
Insert seal must be clean and dry
for a proper seal!
NOTE:The insert seal must be dry to work prop-
erly. Insert Seals typically last 50-60 repairs.
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3. Cant the Fixture Arm
a. Using the adjustment screw, adjust the fixture arm so
the outer chamber is slightly canted in towards the
suction cup of the repair fixture.
4. Final Adjustment
a. If needed, loosen the adjustment lever to re-center the
impact point in the opening of the outer chamber.
b. Once the break is centered, retighten the adjustment
lever.
c. Re-check to be sure that impact point is still centered
before proceeding.
5. Placing the Outer Chamber
a. Turn outer chamber clockwise until you feel the in-
sert seal make contact with glass.
b. Then add ONE FULL TURN –
DO NOT OVER TIGHTEN!
c. Tighten blue knurled nut by turning clockwise.
NOTE:The insert seal must not cover the impact point. If it does,
back out the outer chamber, reposition the fixture arm with the adjust-
ment lever to re-center the impact point with the hole in the bottom of
the outer chamber.
A proper seal is critical. If the seal is too loose, you will have trouble
with the insert seal not sealing during the pressure cycle. If it is too
tight it may cause the break to run, or it may pinch the cracks closed
and keep them from filling properly. Check to see that the red line on
the plunger has not reappeared. Make any necessary adjustments
before proceeding.
Before and After Canting the Fixture
Impact Point
Impact Point Centered in Bottom of
Outer Chamber
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PREPARING THE INJECTION CHAMBER
The injection chamber will hold one AEGIS®Single Shot,
however only a few drops will actually be used to fill the
break. If doing multiple repairs in the length of one day, the
remaining resin can be capped and stored in the injection
chamber. In order for the repair device to operate effectively
the loaded injection chamber must be free of air.
1. Prepare the Injection Chamber
a. Insert piston into injection chamber and screw down until
it stops - about 6 full turns.
b. Use the blue marking on the injection chamber for a ref-
erence mark.
c. With injection chamber upside down place filling adaptor
on end of injection chamber.
d. The resins must be gently mixed before use by turning
the single shot upside down a few times. DO NOT
SHAKE.
e. Open AEGIS®Single Shot.
f. Place the open end of Single Shot slightly inside the
adaptor.
2. Check the Resin
The resin should be a clear liquid. If it is cloudy or contains
particles, DO NOT USE! It is either too old or has been con-
taminated from earlier repairs.
a. Slowly turn piston clockwise to draw resin into injection
chamber.
b. Once all resin is in injection chamber, carefully rotate pis-
ton counter-clockwise to push any extra trapped air out of
the injection chamber.
c. Rotate piston clockwise to draw the air-free resin back
into the injection chamber, stopping when a small amount
of resin is still visible at the opening of the injection cham-
ber.
d. Remove the filling adapter.
3. Lubricate the O-Rings
a. Using a gloved finger, lubricate o-rings on injection cham-
ber with alcohol.
4. Place the Injection Chamber
a. Place the loaded injection chamber into the outer cham-
ber.
b. Line up the blue indicator line on the injection chamber
with the hose plug on the outer chamber as a reference
point.
5. Turn injection chamber 2 ½ clockwise turns, slightly past
the point where you feel the seal engage. The repair fixture
is now in position to draw the primary dry vacuum.
Turning the Injection Chamber
Drawing resin into the
adaptor and Injector
QuickSilver Technology ™
Chamber
Piston
Cap
O-Rings
Injection Chamber
Piston Knob
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PRIMARY DRY VACUUM CYCLE
The primary vacuum evacuates air and moisture from the
break.
1. Attaching Hose
a. Attach the quick-connect socket on the hose assembly to
the hose plug on outer chamber. To make these con-
nections, pull back the sleeve of the quick-connect
socket and push it firmly onto the plug. Release the
sleeve and the socket should snap into place.
b. Attach the other end of hose assembly to the vacuum
pump in the same manner.
c. Give the hose a gentle tug to check the connections.
2. Initiate Primary Vacuum
a. Pump the vacuum cylinder 2-6 times. This creates a
vacuum that will draw out any trapped air and moisture
from the break.
b. Monitor the gauge. Gauge readings should remain at
approx. 23 - 25 inHg. Readings will vary slightly due to
altitude and barometric pressure.
3. Maintain Vacuum
a. Hold the vacuum for a minimum of one full minute.
▲TIP:Can’t maintain a vacuum? Turn the knurled nut ¼ turn
clockwise and initiate vacuum again. If this does not solve the
problem, consult Troubleshooting Guide.
▲TIP:Applying heat to the inside of the windshield using a
lighter or AEGIS®Moisture Evaporator during the vacuum cycle
will effectively remove moisture and trapped air from the break.
Too much heat can run a break. When
heat is used, always allow windshield to
cool before continuing.
Primary Dry Vacuum Cycle
Pump Gauge Holding
25 inHg of Vacuum
Attach the Hose Assembly to the
Repair Fixture
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INITIAL PRESSURE CYCLE
During this cycle the injection chamber is lowered to the lowest
point and blocks the primary vacuum. Hydraulic pressure from
the piston rotation injects resin into the break. Typically the
break is filled in 1-3 seconds.
1. Lower Injection Chamber
a. Screw injection chamber clockwise (down) until it stops,
about 3-4 full turns.
b. Remove the hose assembly from the repair fixture by pull-
ing back on the quick-connect socket.
2. Inject Resin
a. Rotate piston knob clockwise until you feel a slight
amount of pressure, then back it off by turning the piston
knob counter-clockwise.
b. Rotate the piston knob clockwise again and you will no-
tice the break beginning to fill with resin.
c. If necessary, repeat clockwise and counter-clockwise
rotations of the piston to open the break and fill it with
resin.
d. This process usually takes about 1 minute for a typical
break.
SECONDARY VACUUM CYCLE
When the piston is retracted it causes the initiation of the sec-
ond vacuum which draws out the remaining air released by the
initial injection.
Retract the Piston
a. When the outer tips of the cracks are almost filled, rotate the
piston knob counter clockwise 3-4 turns to create the second
vacuum cycle.
▲TIP: If after rotating piston knob to inject resin, you find there
is no resin filling the break, then the o-rings on the piston may
need to be replaced. O-rings typically last about 200 repairs.
(SBX2019 & SBX2021)
▲TIP: Applying heat to the inside of the windshield using a
lighter or AEGIS®Moisture Evaporator during the vacuum cycle
will effectively remove moisture and trapped air from the break.
Initial Pressure Cycle
Turning the Piston Knob
Watch carefully! Too much pressure can
cause the break to run or to cause the
glass to separate from the laminate creating permanent
damage. In either case, back off the pressure immediately.
Then reapply pressure at a slower and lower level.
Secondary Vacuum Cycle
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