46 Chetwynd St., Loganholme, Queensland, 4129, Australia
P07 3806 1944 (+617 3806 1944) F07 3209 7711 (+617 3209 7711)

POUR On GLOSS

Usage Instructions The CRYSTAL CLEAR Finish

POUR On GLOSS is a two component plastic resin which can be poured over a level surface and then sets to a hard, strong, non-brittle, glossy coating. POUR On GLOSS can also be applied to uneven surfaces & statues by pouring & brushing.

It can be Post Cured to with stand surface temperatures of 80-85^oC & therefore prevent marks from hot coffee cups, etc. POUR On GLOSS (POG) is not recommended for outdoor use unless it is sealed with AQUACOTE Polyurethane Clear finish which has excellent UV qualities and is extremely tough.

POUR On GLOSS is resistant to most household liquids and chemicals including Red Wine.

Timber Preparation.

Sand the surface smooth with coarse (80 grit) and then medium sandpaper (120grit). If there are significant hollows / undulations (more than 1 to 2mm), it may be easier to tape the edges and fill these areas with Pour-On-Gloss (POG) before commencing the final pour if you want to achieve a level surface.

Tip: When filling low areas do it in layers of 1 to 2mm. This allows time for the air bubbles to rise to the surface before the POG gels. As soon as the POG has gelled and all air bubbles removed (as detailed under Bubble removal), apply another layer of POG. For deep areas it could take several pours to fill completely. Do NOT be impatient or you will end up with air bubbles through your clear finish and they show up like the proverbial “dogs thingies”.

Note: Be careful not to use open coat sand paper (the white or grey sandpaper) as it has a wax / Silicon or some other secret ingredient which may contaminate the surface and prevent good adhesion. Yellow, Black, Red or Green sandpaper is fine to use.

Round the edges and the corners with a generous radius (12 to 20mm) if Pour-On-Gloss is to flow over the edges, otherwise the coating will become very thin on the edges. If you do not want Pour-On-Gloss to flow over the edges tape the edges with Duct Tape with the tape at least 2mm above the work piece edge to contain the POG and ensure an even coat across the surface.

Tape the back of the timber to block cracks and imperfections which penetrate through the timber. This is to prevent the POG ouzing out and being wasted.

Tip: Use sticky or Duct Tape. Stretchable tape is preferable to use as it is less inclined to crease and is easier to apply to the surface and to remove later on.

Note: Do not use paper based masking tape as the POG will seep through and cause the tape to bind to the POG.

Fill holes and cracks with POG if you want to show the cracks as a feature or they are small. Also BOTE COTE epoxy resin mixed with filler can be used for large cracks and depressions. The filler can be saw dust or BOTE COTE sanding filler, and a spirit based tint such as Feast Watson Prooftint or Bote Cote pigment could be added to achieve a desired effect.

Tip: Use a syringe with a draw up needle to get the epoxy right down into small holes and cracks.

Tip: Only mix amounts that can be used in 15 minutes as the gel time is 15 to 20 minutes depending on the air temperature.

Note: Do not thicken epoxy being used to fill small cracks as it will not flow freely into them and could leave holes when sanded.

When ready to do the final sanding, wear gloves so that skin oils do not transfer onto the surface and contaminate it. Remove all dust carefully (not by blowing from your mouth, it will put saliva on the surface). You could use compressed air to blow the dust off, or a lint free clean rag which has been dampened. Remember, wear gloves.

Sealing Porous Surfaces

Porous surfaces can be sealed before casting, otherwise air bubbles may be expelled into the coating. Prepare a small amount of Pour On Gloss, and mix it into an equal volume of Acetone. Brush a thin coating of this onto the surface and wait until it has become tacky before casting the final gloss coating. If applying photo’s & keepsakes, wait until it has become dry and then sand lightly before applying photo’s & or keepsakes.

Another technique is; when ready, warm the timber up so it is warmer than the surrounding air. Therefore, it will be cooling when the POG is applied. This way, voids in the timber will “suck” the epoxy in, instead of releasing air bubbles.

Photo & Keepsake Attachment

Glue photo(s) & other graphics on with a glue stick, spray on adhesive or water based glue & leave until thoroughly dry. They should be sealed with a thin coat of a clear water based sealer & leave until thoroughly dry, before casting the Gloss Coating. This will ensure that the inks do not run under the Pour On Gloss.

Metal items, shells, bugs & other keepsakes can be attached using a small amount of Quick Set Epoxy or Super Glue.

Final preparation for coating

Ensure final preparation is carried out under cover away from direct sunlight in a dust free environment with the air temperature between 20 & 30⁰C. At this temperature range there is about a 15 to 20 minute pot life.

Note: Below 20^oC the Epoxy will be too thick and over 30^oC it will gel too fast.

Prepare everything you will need before starting a pour. This should include:

· Plastic sheeting or cardboard placed under the area to catch the inevitable epoxy drips which come from the sides.

· Supports to sit the work piece in an elevated position to allow extra mixture to drip off. Clean small plastic buckets & unloved plant pots are ideal.

· Use a spirit level to ensure the work piece is perfectly level, otherwise the Pour On Gloss will not be evenly applied.

· A dust cover - It could be a laundry basket which has glad wrap around it. Also a clean cardboard box could work well. It is best if it is clear to enable you to see where the cover is being placed to ensure you do not touch any surface.

Prepare Pour On Gloss

· Warm Part A to about 30^oC to ensure it is very fluid.

· Pour equal amounts of Part A & B into the same measuring cup only mixing about 500ml at a time. Too much and it will become hot and gel too fast. Never measure into separate cups.

Note: Never add more hardener to make it set faster - it won’t. It will result in an inferior & less resistant coating.

· Mix thoroughly & fast ensuring around the sides & bottom are scraped to pick up unmixed epoxy while continuing to mix for one to two minutes.

· Then pour into a second plastic container & stir again for one to two minutes to ensure all POG is mixed. This is important to ensure the epoxy is thoroughly mixed.

TIP: Prepare the container by placing a hole (approx. 6mm diameter) in its side at the bottom & seal it with a small piece of insulation tape.

· Then remove the tape from the hole in the bottom and allow the mixed POG to pour, holding the container approximately 100 to 200mm above the work piece.

TIP: This technique aids greatly in reducing bubbles in the poured POG as large bubbles break during the pour & the a lot rise to the surface in the container.

Apply POG to Work Piece

Move the container around the work piece in a spiral pattern starting at the centre, thus delivering the material evenly across the work piece. Don’t apply too thickly as it will prevent all bubbles rising to the surface. On a flat surface each pour will apply a coat approximately one (1) mm thick.

When the pour is completed, cover it immediately to keep any air borne dust from the surface & leave for five to ten minutes to allow time for bubbles to rise to the surface.

TIP: Use a brush or tongue depressor to assist the POG to evenly coat uneven edges and to flow over the sides.

Bubble removal

The best way to remove bubbles is with a Portable Butane Torch. Holding the torch about 150mm above the surface; wave the gas flame over the surface which causes the bubbles to pop. It may be necessary to repeat the flame treatment 2 or 3 times. A needle can be useful to help lift stubborn bubbles to the surface. Aim to finish all spreading and bubble removal in 15 to 20 minutes after mixing the POG as it will be commencing to gel.

TIP: A heat gun does not work well at bursting the bubbles and tends to heat the POG and create an uneven surface. Also it tends to accelerate the GEL time.

Caution: Do not overheat the resin as it can gel prematurely or worse it could burn if the flame is held stationary.

Anti dust precautions

Take precautions against airborne dust settling on the work. As soon as bubble removal is complete, cover the work with the prepared, dust free cover.

Drips

If the work piece has straight edges, the underside can be taped with duct tape and removed along with cured drips.

Scrape excess drips off after about 45 minutes after pouring, by running a tongue depressor along the underside edge of the work piece.

After this, leave drips until the work piece is fully cured and sand them off.

Curing

Pour On Gloss will gel in a few hours, how-ever it will not be hard enough to handle for perhaps 24 hours and even then only with care. After about 3 days, it will become quite hard and able to withstand normal handling. The colder the climate the longer it will take to Gel & set to full strength. If low air temperatures are present heat the work area to above 15^oC until the POG is fully cured.

Note: If the air temperature falls below 10^oC the Epoxy will stop curing until the temperature rises above 10^oC again.

Overcoating to fix problems

If the outcome is not quite what you wanted, then sand the POG with coarse sand paper (80 grit) ensuring all gloss is removed. Dust the surface carefully, using a clean, damp rag to remove any residual dust. Wear gloves, remember your fingers have skin oils on them which can also interfere with the final result.

Repeat the steps in relation to pouring.

Post curing

We have put a coffee cup on a POG piece with 90⁰C water in it. This did result in a minor semicircular mark. We then put the piece in our oven and kept it there for 3 hours at 75⁰C. Not only did the semi circular mark disappear, but after this, the cup did not leave any further marks from coffee cups with 90^oC water in them.

TIP: A car interior becomes an excellent Post Curing Oven on a hot day.

Final Steps

The finish can be buffed and polished. If the surface is going to be used (say as a bar top etc.) we recommend overcoating with Aquacote Clear, our 2 pack, water based polyurethane which is extremely hard and very scratch resistant. This too can be cut and polished to achieve a high lustre.

The rear of the piece should also be coated in epoxy otherwise, it will allow the moisture content of the timber to vary with atmospheric conditions and the expanding and contracting will cause unevenness in the POG finish.

Safety Directions

· Avoid contact with eyes or skin.

· Avoid Breathing dust & vapour. Ensure there is good ventilation.

TIP: Place a fan so any dust or vapour is being blown away from the work area.

· Wear eye protection and gloves when mixing & using.

First Aid Directions

· If skin contact occurs, remove contaminated clothing and wash off with White Vinegar then with soapy water or BOTE COTE Hand Cleaner.

· If ingestion occurs contact a doctor or poisons centre. The MSDS is available on the BoatCraft Pacific Website.

· If in eyes; hold eyes open, flood with water for at least 15 minutes and see a doctor.

Enquiries

Please call Boatcraft Pacific 07 3806 1944 ( +617 3806 1944) for how to contact your nearest reseller.