545 Epoxy PrimerSpray Only
Air-atomized and airless spray setup, viscosity, gun configuration, and coat-by-coat technique for Awlgrip 545 Epoxy Primer. Verified against the official Awlgrip 545 TDS and Awlgrip Application Guide gun-setup charts.
Before you load a spray gun with 545, watch Bob’s walkthrough. He runs Awlgrip’s YPAC (Yacht Paint Application Center) training program and is one of the best technical resources in the marine coatings world. Fiberglass Florida works closely with Bob — his guidance is the same advice we give at our Rockledge and Stuart counters every day.
▶ Bob — YPAC Application Training Fiberglass Florida YouTube →545 Epoxy Primer contains isocyanates. A supplied-air respirator is required for spray application — an organic vapor cartridge respirator is not sufficient for overspray and atomized isocyanate exposure. Maintain continuous fresh air flow in the spray area. Read the full SDS at fiberglassflorida.com/sds before spraying.
Why Spray 545?
Spraying 545 Epoxy Primer delivers a more uniform film thickness, faster coverage on large surfaces, and a smoother base for topcoat than brush or roller application. It is the preferred method for hull-sized jobs, full repaints, and any project where surface uniformity directly affects the final Awlgrip topcoat gloss and DOI (distinction of image). This guide covers spray-only setup, reduction, and technique — for brush and roller work see the 545 Roll & Tip Guide.
545 is a lower-viscosity epoxy primer and is best suited to air-atomized spray equipment (conventional or HVLP-style guns). Airless equipment is intended for higher-viscosity products like High Build, Ultra Build, and fairing compounds — not 545. Use air-atomized setup for the best finish on 545.
Mixing for Spray
| Component | Part | Ratio |
|---|---|---|
| 545 Base (D8001 white or D1001 gray) | Part A | 1 Part |
| Converter D3001 | Part B | 1 Part |
| Induction time after mixing | — | 15 minutes minimum |
| T0006 Spray Reducer (added after induction) | Reducer | Up to 25% |
| Pot life at 77°F / 50% RH | — | 16 hours |
Mix Base and Converter D3001 1:1, stir for 2 full minutes, then wait the full 15-minute induction period before adding T0006 reducer or loading the gun. Applying before induction is complete results in under-cured primer that may not adhere properly to the substrate.
Spray Gun Setup — Air Atomized
545 Epoxy Primer is grouped with Awlgrip, Awlcraft 2000, Awlcraft SE, and other lower-viscosity Awlgrip primers for air-atomized application. The settings below are taken directly from the Awlgrip Application Guide DeVilbiss gun-setup charts for 545 on small-to-medium areas.
| Gun Type | Fluid Nozzle | Approx. Fluid Flow | Handle Air Input Pressure |
|---|---|---|---|
| Gravity (AV-645-FX) | 1.1–1.2 | 180–210 ml/min | 1.8–2.5 bar (26–36 psi) |
| Gravity (GTI-213) | 1.0–1.1 | 160–190 ml/min | 2.0–3.0 bar (29–44 psi) |
| Suction (JGA-421-FX) | 1.1–1.2 | 160–190 ml/min | 2.0–3.0 bar (29–44 psi) |
| Pressure Pot (small areas) | 1.1 | 170–270 ml/min | 2.5–3.5 bar (36–51 psi) pot |
These settings come straight from Awlgrip's official DeVilbiss gun charts, but most quality HVLP or conventional guns with a similarly sized fluid tip (around 1.1–1.4mm) will perform well on 545. Match viscosity by spray-out test, not just gun model — see the 3-Step Fan Check below.
Airless Reference (For Comparison Only)
If a job calls for spraying 545 over a larger hull section using airless equipment, Awlgrip's reference airless settings are:
| Equipment | Specification |
|---|---|
| Airless Orifice | .028″–.043″ |
| Airless Fan / Angle | 8″ / 80° or 6″ / 60° |
| 25:1 Pump Input | 4.8–5.5 bar (70–80 psi) |
| 40:1 Pump Input | 3.4–4.1 bar (50–60 psi) |
The Ten Steps to Success
Awlgrip's Application Guide lists ten equipment and technique fundamentals for any spray job. The ones most relevant to 545 spray application:
Use Clean, Well-Maintained Equipment
Run air through a clean tack rag for 10–15 minutes to check for contamination. Replace dirty air hoses and service filters/traps regularly. Equipment condition directly affects film quality.
Check Environmental Conditions
Temperature, humidity, and airflow all affect spray performance. Confirm conditions are within the application window (55°F–105°F, and at least 5°F above dew point) before spraying.
Choose Reducer & Reach Spray Viscosity
Add T0006 Spray Reducer after induction, up to 25%, to reach proper spray viscosity. Reduction level needed varies with ambient temperature — hotter days may need less reducer, cooler days more.
Run the 3-Step Fan Check
Before spraying the actual part: (1) trigger the gun to confirm even atomization with no spitting, (2) check fluid flow rate and air pressure at the gun, (3) spray a test pattern on cardboard or a scrap panel to confirm an even, properly shaped fan with no heavy edges.
Spray a Test Area First
At the start of the job, and before each coat, spray a section of a separate test panel and check appearance and wet film thickness before committing to the full surface.
Work Within the Pot Life
As mixed 545 continues to induct and react, its rheology changes. Spraying late in the pot life can affect atomization and final film appearance — mix smaller batches if you're working slowly.
Coat-by-Coat Application
Surface Prep
Sand gelcoat/fiberglass with 100–150 grit, aluminum to a 2–3 mil profile, steel to SSPC-SP10/Sa 2½, wood with 80–100 grit. Surface must be clean, dry, and free of wax, oil, and release agents before spraying.
Mix, Induct, Reduce
Mix 1:1 Base to Converter D3001. Wait the full 15-minute induction. Add T0006 up to 25% to reach spray viscosity. Strain the mixed material through a paint strainer before loading the pot or cup.
Spray Coat One
Apply a wet coat at 7–10 mils WFT targeting 2–3 mils DFT. Maintain consistent gun distance (typically 6–10 inches) and overlap each pass by 50% for even coverage.
Recoat Within 1 Hour (or Wait 12 Hours)
545 can be recoated with itself starting at 1 hour minimum. If you miss that window, the next recoat with itself or other Awlgrip products is 12 hours. Don't recoat in the gap between 1 and 12 hours.
Apply Coat Two (and Three if Needed)
Repeat at 7–10 mils WFT per coat. Most jobs need 2–3 spray coats total. A third coat is common on rough, repaired, or heavily sanded surfaces to ensure full, even coverage.
Sand Before Topcoating
Maximum recoat without sanding is 24 hours. Sand with 320–400 grit before topcoat for best adhesion and gloss. Remove all dust and wipe down before moving to the topcoat stage.
Coverage & Film Thickness
| Coverage | Value | Notes |
|---|---|---|
| Theoretical (1 mil dry) | 497 sq ft/gal | Mixed base + converter, reduced 25% |
| At recommended DFT | 165–248 sq ft/gal | Varies by equipment & technique |
| Wet film thickness (per coat) | 7–10 mils (175–250 microns) | 2–3 spray coats |
| Dry film thickness (per coat) | 2–3 mils (50–75 microns) | Target total system |
Recoat & Cure Times — 77°F / 50% RH (Spray)
| Stage | Time | Notes |
|---|---|---|
| Recoat with itself | 1 hour min | Per Awlgrip TDS |
| Recoat with other Awlgrip products | 12 hours | High Build, topcoats, etc. |
| Maximum without sanding | 24 hours | Sand for best results |
| Full cure | 7 days @ 77°F | Faster in FL summer |
| Minimum application temp | 55°F (13°C) | Do not spray below 55°F |
| Maximum application temp | 105°F (41°C) | Or within 5°F of dew point |
FAQ
Supplies for Spraying 545
Have these on hand before you mix — running out mid-job costs you pot life and can force a bad recoat window.
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