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1) thin layer (or two) of epoxy over XPS; let it get tacky (or let it dry and sand). Then a fresh layer of epoxy and glass on top of it (epoxy penetrates into glass from the bottom and wets it out. 2) Same as the first step but without any extra epoxy layers in advance - just a fresh layer followed by cloth on top immediately.
As far as I am aware the problems with polyester gelcoat and epoxy stem from fast commercial moulding of parts where the gelcoat is put in mould followed by the epoxy/fabric/core etc layup. For this reason products like Tycoat exist. I have used this technique of a thin 'seal' of polyester quite a bit on vinylester, epoxy and polyester layups.
OK, after spending considerable time searching the web, it seems the most suitable resins for chemical resistance to gasoline (octane, toluene, benzene etc) including ethanol blends are;
I use the Duratec vinylester hi build primer frequently as my final fairing step (over epoxy). To minimize blush problems throughout the process I use a peelply during laminating, and the non-blushing West 207 hardener for fairing. Make sure the epoxy is well cured, washed, and coarsely sanded. You should have no problems.
30 – 70 193 – 203 < 200 9.6 Liquid epoxy resin pre-catalyzed for subsequent up-staging. EPON 8280 Modified DGEBPA 110 – 150 185 – 195 < 50 9.7 Anti-foaming and anti-settling modified liquid epoxy resin for systems with fillers and pigments. EPON 8281 Modified DGEBPA
Polyester resin has very poor adhesion without mechanical key. Epoxy, OTOH will still stick. It would probably stick much better with key, but the adhesion will probably be quite adequate even without carefully abrading every square inch. For this reason, epoxy is probably the best way to go.
The sizing melts and becomes part of the resin/hardener mixture in polyester/vinylester laminates, but with epoxy, some of the sizing types just remain in suspension. Simply put, the notion that these sizing/binder materials don't work with epoxy, is just the inexperience of the polyester product seller showing.
Paint over epoxy Capt Chris, It has been said that epoxy will adhere to almost anything but im not so sure anymore. Epoxy is just a better resin but i just don't mix materials anymore. Talk to a paint shop or to a paint representative. Especially those that finishes cars. They are very knowledgeable on this matter if it will make you feel better.
Perfection is applied over a product called Interlux Epoxy Prime Coat. The primer is applied over properly cured and prepped bare epoxy resin. These two part LPU's are very hard and wear very little over time. You can sprinkle a product called Intergrip, a non-skid compound, over the wet paint and make yourself a nice secure deck.
Our 1708 for example works with any epoxy. Most of the time, you do not need mat when working with epoxy. The mat is there mainly to provide a decent bond between two layers of directional of woven cloth. With epoxy there is no bonding problem, so you just use the woven or direction right over top the previous layer.