Do not sand green epoxy it smears and will not clear with curing. If you have a smear the solutions are to scrape it off with a cabinet scraper, wait for the epoxy to cure then sand it off, paint the hull or live with the smear showing. If you sand it off you may need a cloth patch. Do not sand into epoxied wood because the wood will lighten and will not redarken when rewetted with epoxy.

You have two options applying fill coats. First is coat, cure, sand and repeat or the second is coat, set, repeat. The number of fill coats depends on the thickness of epoxy and the cloth weave. I use Raka and it takes me four fill coats to fill the weave of 6 ounce e-glass. The unsanded fully-filled fill coats will still have some weave texture even though the lows are filled to above the weave. If the epoxy does not blush and is not cured enough so to still dent from a fingernail you can recoat without sanding between coats. I use the fast hardener for fill coats and can do four coats in one day. Some people brush, some squeegee and some roll. I roll and tip off with a foam brush for fewer runs. If the epoxy triggers while tipping the foam brush drags and then sheds bits into the coat so get new brush if it starts to drag.

You need a full cure to do your final sanding. Final sanding too early may lead to telegraphing (the epoxy flowing when the finished kayak gets too hot in the sun and the cloth weave textures the finished surface).

I dry sand the epoxy because wet sanding masks when you are sanding into the cloth. (However wet sanding is necessary when you do the varnish or the sandpaper will clog quickly.) I usually still need to do one more final fill coat after sanding to fill any bubble pocks (bubble in the epoxy half sanded away) and shiny dimples (weave lows not filled enough to get sanded) and to seal any cloth touched by sanding.

Use a cabinet scraper to remove green or hard cured runs; it will only remove the run.

Dave

: This post follows another post regarding sanding, but I thought i'd
: start a new thread so not to steal anyones thunder.

: I have wet-out the fiberglass on the hull exterior and squeegee'd
: off all the excess and i'm fairly certain it was absolutely
: perfect. Next I repeated the process for the fill coat, again
: using a squeegee to remove all excess (not as perfect, but
: pretty close, i think). I'm still noticing some of the weave
: showing through (Normal?). I've done a light sanding which shows
: up a little splotchy for reasons i'm unsure of, but have removed
: any noticable runs and other high spots. Since some of the weave
: still shows I plan to apply a 3rd coat of epoxy, but..... should
: I proceed applying and squeegeeing as I have the previous 2
: coats, or, should I use a roller and foam brush to apply/smooth
: the new layer?

: Thanks!
: Damian