These are all very helpful suggestions. Lets face it, Hysol/Aero-poxy is the "motar" that holds our planes together and as David mentioned there is nothing worse than trying to remove glue that did not properly cure. After having suffered similiar problems in the past I added one procedure to the "mix" that has fixed that problem. After removing the cap from the Hysol cartridge I insert an exacto blade,#11, into the exposed glue and remove the brown glue . Wipe the blade off with a paper napkin and repeat the clean-out on the white glue. Some times one or the other or both sides of the cartridge will leak around the cartridge divider or septum and plug or thicken the glue enough to cause the uneven flow that David was refering to. This cleaning prep onlly takes about 15 seconds or so and my experience has been that when done I always get a good result. I now perform the clean-out every time I use it. Less waste and really strong joints.

Ad Clark
BVM-rep