this invention teaches methods of making a hermetic terminal assembly comprising the steps of : inserting temporary stops , shims and jigs on the bottom face of a terminal assembly thereby blocking assembly core open passageways ; mounting the terminal assembly inside a vacuum chamber using a temporary assembly perimeter seal and flange or threaded assembly interfaces ; mixing a seal admixture and hardener in a mixer conveyor to form a polymer seal material ; conveying the polymer seal material into a polymer reservoir ; feeding the polymer seal material from the reservoir through a polymer outlet valve and at least one polymer outlet tube into the terminal assembly core thereby filling interstitial spaces in the core adjacent to service conduits , temporary stop , and the terminal assembly casing ; drying the polymer seal material at room temperature thereby hermetically sealing the core of the terminal assembly ; removing the terminal assembly from the vacuum chamber , and ; removing the temporary stops , shims .