Improved and lower cost sealing of aerospace structure

An improved sealing method has been developed for the exposed metal fastener surfaces of the Solid Rocket Booster vehicle for the Space Shuttle launch system. The method employs properly sized flexible plastic caps filled with catalyzed polysulfide sealant, frozen and stored. At the time of use, the caps and sealant are thawed and positioned on the fasteners. The sealant covers the exposed portion of the fastener and prevents salt water damage. The method is one of high reliability with low installation and inspection costs.