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I too am extra crefull, I've got the ratio down to about1 in 50 or so with dry spots.... what everyone else says is what I do,and then some, I use assorted paints, mostly Delta ceramacoat, I have a coelesing filter on each air line to each brush to rule out contamination in my air system....,once the plug is painted, I install the eyes and belly gromets then apply an even, thin coat of acrylic clear as a scratch coat, after that, all plugs are handled with powder free rubber gloves... I scuff with extra fine scotch brite that has been washed in denatured alcohol and air dried and wipe with a chemical free tack cloth and do any final rigging at that point..
I have my acid brushes prepared ahead of time, to do this, I add a thin line of super glue along the base of the brush where the bristles attach, when the super glue is dry, the brushes are washed in denatured alcohol and allowed to air dry.... I then seal them in a plastic bag...
Epoxy is applied in a medium thick coat then"scraped" off with the brush, working the epoxy both ways, fore and aft on the plug...
the plugs are sent spinning and the doors closed.. once the timer shuts off(2 hours), the plugs are left alone for 48 hours before I touch them....
and in the rare instance I get a "dalmation" I simply scuff,wipe and reapply another coat... never had one fail a second time...
alot of work... yes... but durable..
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