Primary mirror aluminizing operations at the Large Binocular Telescope

We summarize the operational realities of re-aluminizing 8.4-meter primary mirrors in-situ on the Large Binocular Telescope. We review the evaporative coating system design, and summarize its performance in the 16 coatings since 2005. A mostly manual system with long-handled mops and traditional chemicals is used to remove the old coating and to clean the glass surface. After cleaning, the telescope is moved to horizon-pointing orientation and the aluminizing belljar is mounted to the primary mirror cell using the overhead crane internal to the enclosure. We report on the multi-year struggle to understand variations in deposition rate among the 28 crucibles that evaporate the aluminum. We describe the challenges of making operational improvements to a system that must reliably coat one of the two primary mirrors every year, and we report on some lessons learned along the way.