Method of making direct tension indicating washers

1. A method of making a direct tension indicating washer comprising:

forming a first surface having a discrete protuberance formed thereon;

forming a second surface having a discrete indentation formed opposite the protuberance;

positioning an indicating material in the indentation; and

curing an external portion of the indicating material to form a cured skin of indicating material on an outside of the indicating material and a liquid core in an interior of the indicating material.

2. The method of claim 1 wherein the indicating material is mixed under nitrogen prior to being polymerized.

3. The method of claim 1 wherein the indicating material is mixed under ultra-dry air prior to being polymerized.

4. The method of claim 1 wherein the cured skin is formed by initiating polymerization of the indicating material and terminating the polymerization upon formation of the cured skin.

5. The method of claim 4 wherein polymerization is terminated by applying energy to the indicating material.

6. The method of claim 5 wherein the indicating material includes a catalyst for terminating the polymerization when activated by heat.

7. The method of claim 1 further comprising forming a channel leading from the indentation to an outer diameter of the direct tension indicating washer.

8. The method of claim 1 further comprising:

forming a plurality of discrete protuberances on the first surface;

forming a plurality of discrete indentations on the second surface has, each indentation formed opposite one of the protuberances; and

forming a plurality of channels in the second surface, each channel leading from one of the indentations to an outer diameter of the direct tension indicating washer.

9. The method of claim 6 wherein the catalyst is a platinum based catalyst.