I installed my mortar screen today. Here's my last screen cleaning, using the original screen (in use for probably 2+ years, I would have to look back to see when I actually put it into use)
So it's not like that wasn't working well....
Here's the new screen
I shot a bunch of video while I was making this screen (made 4 actually) and I"ll be throwing that up on YouTube soon.
Basically, I roughed up the screen initially with my stage 1 process as usual, which is a wire brush drill attachment. This preps the screen to better accept the mortar, otherwise, it slides off really easily.
I taped off the top edge of the screen (that gets inserted into the slot) plus the next 2 rows prior to the stage 1 rough-up, then I took that off and cut the screen down to it's final size. Then, I added the tape back to protect the top edge from mortar.
I slathered on the mortar really thick, like 1/4" all over the screen, then flipped it and "massaged" it so that it pushed up through the other side, making sure to coat the entire screen.
Then I used a toothbrush and squeegeed off the bulk of the mortar, which left the holes filled in but the screen pattern showing.
After that, I held it over a garbage can and used the toothbrush to swipe the loose mortar off the screen, flipped the screen and brushed more, and repeated that about a half dozen times. The result was what you see in the pics above: the mortar and the fine particles of the mix were stuck to the screen, with only a small percentage of the holes filled in. Most of the sandy/grainy particles got brushed away.
Next, I sandwiched this between 2 pieces of wax paper, put it in a container (sterilite bin) and placed a wet hand towel on it. I let it cure for 2 days, spritzing it with water once or twice/day. I was surprised that the mortar was very flexible and not at all brittle by this point. I expected to hear crackling when I bent the screen, but it flexed right with the screen.
I placed the screen in a 5g bucket with RODI and changed that water after 4-5 days. Soaked a total of 7 days, then swished it in the bucket (not much came off) and then ran it under tap water and scrubbed it a bit with a toothbrush. I thought a good amount of mortar would come loose when I did that, but it's really stuck on there like glue, hardly any came off at all.
I put it in the scrubber, but I had to remove my false bottom because I forgot about a dimensional difference. All in all, I'm impressed with how easy this was. Way better than roughing up the screen with a saw blade!