Thanks to all for advice. I am using West system 105 with 207 clear hardener, in a warm shop. I have opened the door to ventilate and it cools it a bit but still not really cold. I tried applying with chip brushes and I can brush out fairly thin but it leaves bristles behind which I have to pick out. Will try the foam again. The varnish I bought is the Schooner high gloss, from Chesapeake Light Craft, so it's meant for boats, to be used over epoxy, but I have not tried that particular product. I do have an HVLP sprayer and experience using it with shellac or lacquer on furniture, and was wondering if anyone ever sprays on their varnish.

As for the ROS vs a sanding board, I think the soft pad of the sander conforms to the surface better and I just applied my first fill coat a little too thin, or sanded a little too heavily, or both. Hopefully with a lighter touch I can avoid getting into the weave. I might even try 220 grit so as to go slower. I have used automotive compounds on furniture with a buffer in the past and that is surely much faster than hand rubbing with pumice or rottenstone. It's is true that you have to let all film finishes cure for at least a week or preferably two before rubbing out, since the friction of buffing can soften the film and make it gummy if you do it too early.

Thanks again.
Jay