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[i]The heat shield was manufactured by first bonding the fiberglass honeycomb to a stainless steel honeycomb substructure with HT-424 adhesive tape. The bond line was inspected to ensure that a good bond had been achieved, and the assembly was then cured. After curing, each of the 370,000 honeycomb cells was manually filled with Avcoat ablator using a device similar to a high pressure caulking gun. The filled honeycomb was furnace cured, after which it was finish-machined on a numerically controlled lathe. The heat shield was X-ray inspected to find any voids which were subsequently drilled out and refilled with Avcoat ablator material.[/i]
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