Cosmetic tube between the two Side Tubes

COMPLETED (OUT OF 9)

Tube prep

Is the roll 25" 1/4 wide? If over 25" 3/4, trim.

Cut the 2 ply 60 degree axis roll to 8' length
Label roll (type of material and remaining length) place under table on white shelf
Cut two 4 ply lid reinforcements (3" x 26 ") from a roll for both ends
Tape down reinforcement strips
Press 4 ply lid reinforcements on the large (#1 press)
Trim reinforcement overlap on cutting table

Tube folding

Align material to table edge, and tape

Close hinges over material, clamp
Make sure fabric does not slip
Run teflon covered plank between rails to crease tube (make sure to flatten tube ahead of plank)
After 2 feet of creasing, check for center by folding two edges inwards. Repeat as needed until the tube is centered
Unclamp, unhinge, and remove from tape
Fold one side over along crease, and rub with handled tool to set in creases, repeat for other side
Wipe under seam with alcohol
Lay fiber tape down sticky side up, in the tube center
Peel back 1" from each side of fiber tape, and secure each end with blue tape
Score tape for lid slit (about 1 foot long, 10 inches from the edge)
Pull tape, centering as you go
Rub down the seam tape with a plastic burnishing tool
Wipe over seam with alcohol
Unroll 3" 4-ply strip, wipe with alcohol, flip.
Tape and center 4-ply strip
Place blue tape "X" over lid slit
Seaming

Insert resist under seam strip covering lid slit

Center seam of tube on orange rubber on press
Press length of tube one press width at a time, with 3" of overlap for 30 seconds
Adjust seam strip so that it is centered on the tape
Check for bubbling or untacked edges, and repress
Remove resist

Lidding (1/2)

Pre cut non fiber PSA tape square to the exact circumference of the tube (someone will preproduce 90 of these)
Invert 2" of the tube end with the lid slit, wipe with alcohol, and pull back shiny white backing and place parallel on top of tube lip
Slide tube over mandrel through the lid slit
Place lid end by aligning white non fiber PSA tape strip edge on 5 1/2" wood mandrel
Secure tube with rubber tubing
Remove non fiber PSA tape backing
Remove fiber PSA circle backing, place into tube sticky side up curved upwards like a taco
Using two wood skewers, make sure that the flat circle isn't sticking to the sides of the tube
Using skewers and starting with the seam first, evenly distribute folds towards the center, creating multiple darts
Pinch darts together and fold over, then rub them down in one direction
Clean 4ply 7 3/4" circle with alcohol
Center 4ply circle evenly over darts and rub onto PSA circle to set it in place
Take tube off of wood mandrel and insert the metal pressing mandrel
Angle lid mandrel into press over the 'I' beam, align mandrel bottom with blue tape
Place a clean piece of rubber over lid and press for 5 minutes at 275 degrees
Check for leaks by injecting air. Hold tube closed and soap with sponge, checking for bubbles
Take tube out of press, unwrap rubber tubing, squeeze the tube under the mandrel, and inflate to release tube from mandrel
Peel the backing on the PSA fiber tape in the tube seam
Close tube by pressing seam over the taped lid slit
Remove tube from mandrel, place it neatly folded in a bag and mark the bag "lidded"

Bending
Insert thick rubber into tube
Pull thin red rubber with hose clamps around the open tube end so that it is about 1 foot above the rubber insert
Slide tube with rubber inserted over PVC mandrel and align seam to markings
Pull thin rubber down against PVC rim, tighten hose clamps (make sure hose clamps are not on the PVC mandrel underside)
Align PVC mandrel to the marking on the table
Clamp down outer wooden guides, place tube between inner and outer guides, and inflate
Close air once the tube feels tight, but not stiff and test seam for leaks with soapy water
Bend to guide by pushing the tube outwards from the inner curve of the table
Alternate bending with opening and closing the air valve to increase pressure gradually until the tube seam is uncreased and smooth

Inverting

Clean copper rod with alcohol

Pull tube over rod and flip the tube inside out
Wipe tube along its outside curve with alcohol
Reinforce back with tape, using the tape height tool
Burnish tape down with a plastic tape roll
Invert again
Mark date and proceed to lidding (2/2)

Make fittings

Wrap axle threads six times

Align washers on axles, checked against the inner spacer tool
Match outer washers to inner washers, making sure there is no space between them
Check fit of washers on air inlet

Lidding 2/2

Insert cutting board

Cut slit
Place PSA tape behind cut

Pre cut non fiber PSA tape square to the exact circumference of the tube (someone will preproduce 90 of these)
Invert 2" of the tube end with the lid slit, wipe with alcohol, and pull back shiny white backing and place parallel on top of tube lip
Slide tube over mandrel through the lid slit
Place lid end by aligning white non fiber PSA tape strip edge on 5 1/2" wood mandrel
Secure tube with rubber tubing
Remove non fiber PSA tape backing
Remove fiber PSA circle backing, place into tube sticky side up curved upwards like a taco
Using two wood skewers, make sure that the flat circle isn't sticking to the sides of the tube
Using skewers and starting with the seam first, evenly distribute folds towards the center, creating multiple darts
Pinch darts together and fold over, then rub them down in one direction
Clean 4ply 7 3/4" circle with alcohol
Center 4ply circle evenly over darts and rub onto PSA circle to set it in place
Take tube off of wood mandrel and insert the metal pressing mandrel
Angle lid mandrel into press over the 'I' beam, align mandrel bottom with blue tape
Place a clean piece of rubber over lid and press for 5 minutes at 275 degrees
Check for leaks by injecting air. Hold tube closed and soap with sponge, checking for bubbles
Take tube out of press, unwrap rubber tubing, squeeze the tube under the mandrel, and inflate to release tube from mandrel
Peel the backing on the PSA fiber tape in the tube seam
Close tube by pressing seam over the taped lid slit
Remove tube from mandrel, place it neatly folded in a bag and mark the bag "lidded 2x"

Punching

Check punch sharpness

Fold tube on seam
Check hole centering
Place axle patch
Press patch
Punch holes

Ready for install

Populate
Lube outer washer
Tighten
Check for leaks