Epoxy finish

[OCD]

I'm coating my sides with epoxy to seal it, my plan is to use 3 coats on the outside, 2 on the inside and follow that with 2 or 3 coats of UV protected varnish. I'm finding the finish of the epoxy is very grainy/rough and not as smooth as some appear to be in many of the build logs. Although I will be sanding between coats, could I be using a roller with too long a nap? I have been brushing on the epoxy and smoothing with a roller. Would a foam roller work better or would it be torn apart? What do you use?

Thanks

[doug hodder]

You ought to be using a foam roller made for epoxy application. One of the paint foam ones from the big box stores will tear apart. The epoxy rollers aren't sold at a HD either at least around here...you need to get to a speciality type store, Woodcrafters, West Marine, etc... or order online. After you roll the epoxy on, then take a roller that you have cut in 1/2. Clamp it in a spring clamp and back drag the resin to knock down bubbles and orange peel. It's in the user manuals posted in the stickies. (see West System instructions) Apply with a roller, backdrag with a cutdown roller.

Depending on how smooth you want your finish, 3 layers may not be enough. I'd never pick a "number" of coats, but do it till I'm happy with the results. Doug

[Steve_Cox]

What Doug said. Also good to focus on the plywood endgrain when applying epoxy, fill until smooth.

[afreegreek]

use light weight poly.. apply the resin, lay the poly over it and use a wide 8 -12" drywall knife to "squeege" it smooth.. when the epoxy cures pull the poly. viola! smooth as a baby's bum..

[KenC]

Would a foam roller work better or would it be torn apart? What do you use?

I use a foam brush and "tip" after rolling on with a foam roller.