How to make Thermalite

INSTRUCTION SHEET

MAKING IMITATION THERMALITE IGNITERCORD

WARNING

Compositions and devices discussed herein may be dangerous to formulate, assemble and use. Utmost caution and proper safety practices must be observed at all times. Pyrotechnic compositions discussed herein are extremely sensitive to heat, friction, and impact (chlorates).

Never grind, pound, or pulverize oxidizers with fuels! It is dangerous perhaps disastrous to grind any oxidizer and fuel combination - especially chlorates!

As with most any pyrotechnic composition or device, the compounding and construction of pyrotechnic mixtures and devices should be approached with caution! Their manufacture and use may be neither predictable nor completely reliable to operate as intended. The use of quality materials and a properly equipped workspace is mandatory for safety and good results.

The procedures and results listed herein are that of the author's experiences which may not be outlined listed are to be considered minimum construction techniques. Do not cut corners or use materials other than as listed. To do so would undermine the operation of the completed device.

SAFETY PRECAUTIONS 

1) Always wear safety goggles, rubber gloves and respiratory protection (dust mask) during all operations.

2) Never smoke during operations or mix/prepare compositions near sources of heat or flame (including pilot lights). Always work in a well-ventilated area.

3) Never grind or pulverize different classes of chemicals together- always separately. Never grind oxidizers with any other chemical, metal powder or composition!

4) Mixing should be accomplished by sifting several times through a clean 15 to 30 mesh brass or aluminum screen (these are non-sparking) followed by gently rolling/shaking in a clean plastic container with snap-on lid. 

5) All mixing and production hardware should be plastic, glass, wood, brass, or aluminum and properly grounded using a woven wire mesh grounding strap or similar. Any and all electrical equipment must be grounded in this manner as well as any large metal storage drums being used. Never use iron, steel or their alloys for mixing purposes.

6) Never prepare more composition than you intend to use at a time. Mixtures should never be "stored" in an uncompleted form. In unprotected dry form, many ingredients may be hygroscopic - that is to say, they will absorb moisture from the air causing degradation and poor performance. Use completed devices as soon as possible. Humidity, temperature, geographical Iocation, storage duration and conditions all have adverse effects on pyrotechnic compositions and devices with spontaneous combustion during storage always a possibility in extreme conditions.

7) Always clean tools and equipment before a moist or uncured material has a chance to dry or cure. Dry / cured materials are much harder to remove (if at all) and are much more sensitive to heat and friction and therefore near impossible to remove safely and without damaging tools.

PROCEDURE

The Imitation ThermaliteTM mixtures subject of these instructions is extremely-flammable and are designed to be used in harmony with the Skylighter Tabletop Matchmaking Stand. It coats several cotton strings with the pyrogen slurry thus making the ignition cord. Follow the directions that come with the matchmaking stand to make up to 400 feet per hour. 100 grams of this mixture will make approx. 130 feet of 3/32" diameter igniter-cord. This tooling is intended for use by qualifies adults fully versed and cognizant of the natures of chemicals and mixtures discussed. Utmost caution must be used at all times while formulating, mixing and "pull coating" the igniter cord. Use protective gear such as rubber gloves, safety glasses/face shield.

As the use of this information and/or tooling is beyond our control, user assumes all risks and liabilities and accepts full responsibility for their use. 

For those wishing to use homemade tooling, we offer the following information. The procedure is not as fast as using the matchmaking stand and the yield per gram is usually less.

MATERIALS YOU WILL NEED TO MAKE IGNITERCORD MATCH

Materials you will need to make the match are as follows: Matchmaking Stand (follow directions applied with the stand for making the match), Skylighter imitation ThermaliteTM pyrogen mixtures (flammables - do not include oxidizer) or the chemicals to make your own pyrogen, potassium chlorate and/or potassium perchlorate, rubber gloves (mandatory), binder solution, acetone, #30 cotton crochet string, 6 oz. wax paper cups, paper towels, 3" to 6" C clamp, newspapers to cover bench, wooden spring type clothes pins and a small cable wire threaded through the spring eye of the clothes pins and tightly secured between two points for drying the match.

COTTON STRING USED

The string commonly used is 100% un-coated cotton string in a couple of diameters or "sizes". Although the un-coated stock is rather difficult to fine everywhere, we have tested some we found locally called "100% mercerized cotton crochet". We found it at Wal-Mart but it is probably found anywhere yarn is sold. The sizes we used for our tests were #10, #20, and #30 (#30 being the smallest and most wisely used in out tests). The term "mercerized" refers to treating the string so it accepts dye better (again, this is crochet stock).

BINDER SOLUTIONS

Comments: Commercial nitrocellulose lacquer may be used by thinning it with the appropriate amount of acetone for use in the solutions listed in the chart. However, Skylighter sells the exact same solid NC (stock #C163/NCS) used by commercial manufacturers to make their lacquer. It is sold and shipped in the wet form (25% water) which is dried thoroughly before adding it the acetone as depicted in the binder solution formulation to follow. Using the dry NC to make your lacquer will save you money. Contact Skylighter for pricing @ 800-372-7056 or visit us online.

The binder solution listed employs volatile thinners and/or adhesives that dry rapidly at room temperature and faster under heat. To avoid excess drying while pulling the match, the use of a bottle with small holes drilled in the bottom to pull the strings through and lid drilled to size the match is employed. This eliminates the evaporation of the solvent and ensures a constant flow of material coating the strings. This procedure is employed with the Matchmaking Stand previously mentioned.

Binder Solution: Add 1.50 oz. of dry nitrocellulose to a quart of acetone and allow to dissolve thoroughly. Note: if the composition (coarse materials present as well) does not adhere the throngs as they are pulled through the solution, increase the NC to 2 oz. per quart acetone thus making it thicker and "tackier". Adding a plasticizer to the NC solution will render the finished fuse cord pliable. If you wish this add 1.5 oz. of Triacetin or Dibutyl Phthalate per quart of NC solution. The plasticizer is added only if you want the igniter cord to be pliable enough to bend it without cracking the dry composition off. Leave it out if you are making the propulsive igniter cord (such as Flying Fish Fuse) for use as shell inserts. The plasticizer(s) slow the combustion rate slightly. Note: The binder solution originally used for our tests was binder solution "E" listed in the instructions supplied with the Matchmaking Stand. It is tackier and collects the granulated components of the Imitation ThermaliteTM  Mixture with ease. We list the NC solution listed here. Either way, the results will be practically indistinguishable. 

MIXING & USING THE COMPOSITION

There are two oxidizers that can be used with the flammables mixture (KCLO3 & KCLO4). Potassium chlorate makes the match burn propulsive and it will take off like a small erratic rocket when ignited. The burn rate according  to our tests for a two inch length averaged 3.16 seconds. This type of match is used as aerial shell inserts. Note: Potassium chlorate makes this match very sensitive to friction and shock and should not be used to ignite rocket motors or other applications requiring frictional contact! The second is potassium perchlorate. Our average burn rate for a two inch length was 2.82 seconds but it is not quite as propulsive as the chlorate composition but it is not as friction sensitive as the chlorate match.

For safety reasons, the pyrogen should be mixed in two steps. With eye protection, rubber gloves and respirator mask in place, place the pyrogen flammables mixture in a waxed paper cup add enough binder solution listed to make a thin paste. Add 22 grams of the appropriate oxidizer(s) and mix it in. Add more binder solution until the mixture is like thick honey or molasses, put the binder solution aside and thin with acetone until it is the viscosity of house paint and smooth without lumps. It must be think enough to retain the granulated components evenly throughout the slurry without settling to the bottom. Follow the procedure that comes with e Matchmaking stand if using one and ir not, follow the instruction listed below.

PROCEDURE WITHOUT USING MATCHMAKING STAND

Because solvents are used to make the igniter cord, use a 6 oz. waxed paper cup to hold the match slurry and a piece of thick cardstock punched with a leather punch to size the match. The procedure is simple. Place newspapers on the workbench and floor and place the rolls of string in a box on the floor. Mount a length of wooden dowel on the table above the box and secure the paper cup to the end of it with a thumb tack so it sticks out over the edge of the table. From the underside of the bottom of the cup, make 3 (or 4) tiny holes using an ice pick or similar spaced evenly apart. Do not make the holes too big - only big enough to feed the string through. Feed the string through the holes and secure out over the sides of the cup temporarily with a clothes pin or paper clip. You will also need some wooden spring type clothes pins and a small cable wire threaded through the spring eye of the clothes pins and tightly secured between two points for drying the match.

Procedure: Cut a piece of thick cardstock to cover the cup and punch a 3/32" hole in the center using a leather punch or similar. The size of the hole will be the size of the finished match. Tape one side of the cardstock to the cup so it lifts up for filling and thinning. Punch the string holes in the bottom of the cup and insert the strings. Pour the "slurry" into the paper cup with the string, feed the string through the sizing hole, close the lid and slowly pull the string cord up through the sizing hole. Cut it with scissors 2 inches above the sizing hole so it drapes over the side of the cup and doesn't slide back into the cup. Hang the cord by the clothes pins you have secured as previously  explained and allow to dry fully. Repeat this until all composition is used. The frying time will depend on the binder solution used but 24 hours would be 24 hours would be minimum. Note: thinning the slurry occasionally with acetone may be required as it evaporates rather quickly if not covered or enclosed. Do so as needed. If it becomes too thick, it will not coat the strings as intended. If too thin, not enough of the slurry will be deposited on the strings. The more composition on the cord, the larger the flame and spark front of the burning match and the higher the radiated heat. After all, the reason you are making the igniter cord is to increase the combustion heat to reliably ignite stubborn formulations or devices.