Three coats of Awlgrip applied. We tried a couple techniques before we settled on the best approach.
We mixed about 24oz of paint and thinned it with 2.5 oz of T00031 thinner (10 percent). We poured it into a foil lined small roller pan. Same as when we painted the cabin top. We rolled and tipped the Awlgrip as we have for other projects. 4" foam hot dog roller and tipped with 2" foam brush. We had a couple curtains. I was not impressed with the over quality. We worked side to side along the mast. We just could not move fast enough to keep a wet esdge while rolling the paint out. We did not have it thinned enough. I sanded the next day careful to remove the curtains. We also had mixed too much paint.
For the second coat we mixed only 15oz of Awlgrip and thinned with 3 oz of thinner (20 percent) and then poured it into two 12oz cups with unloading rods installed in the cups. Just the same as when we varnish. Gayle painted one side and I, opposite her, painted the other side. We painted about 8-10" at a time tipping back towards what we had just painted keeping a wet edge. We moved quickly along the 52' long mast. Just like when we varnish. It worked very well. We tipped with the same brush we applied the paint with, just like varnish. We replaced the foam brushes about every 12-15' as we went along because the solvents cause the foam to slowly swell and get soft. Gayle's side was perfect. I had a few curtains. About 2/3rds of the way down the mast I decided to apply the paint exactly the same but started final tipping with a dry foam brush--so I was using two brushes. I held the paint dispenser and the dry tipping brush in one hand and applied the paint and stroked it out with the other brush. Then, switched brushes and tipped with the dry brush. About every 12-15' I dropped the foam brush I was painting with and then used brush I had been tipping with to apply the paint then drew a dry brush out of my pocket as the new tipping brush and kept going. Perfect results. We sanded the next day very lightly. Had a couple days of rain. Finally, got some good weather. Wiped the mast dry and then wiped it down with denatured alcohol and started in on the third coat. Again, about 15oz of Awlgrip thinned with 3 oz of thinner and split between two cups. She stayed with her one brush technique incorporating a new brush every 12' or so feet. I used the two brush method rotating and replacing brushes same as before. We stayed exactly opposite each other painting about 10" at a time. At the half way point we added more thinner. The paint self leveled beautifully. The mast looks sprayed. I am satisfied...and pleased. The mast has to cure for 14 days before we lift it with a sling and crane to restep it.
We are not experts at applying Awlgrip though we are competent. We painted the topsides about seven years ago. It still looks sprayed even two feet away. That project convinced me amateurs can apply a quality paint job. We painted the cabin top about a year ago. It looks pretty good though not as consistently good as the topsides. I painted the cockpit locker lids last fall. Looks sprayed. And now the mast. What I have learned is you can't be afraid of these projects. Download the info and make a checklist. Have everything prepared. Be patient. It has to be sanded between coats if you are rolling and tipping and you want very good results--same as varnish. You might not be able to sand and paint on the same day if you are outside. Weather is a huge factor. Thinning is critical. It's counter intuitive. You might think thinner paint is more likely to run especially on vertical surfaces. Just the opposite is true. Because it's thinner there is less mass and it's less likely to drip and run. I have consistently found thinning 20-30 percent produces the best results. Do not try to stretch it out when it is apparent you need to add thinner. You will probably need to add more thinner as you go. We should have thinned more and then rethinned at the half way point on the cabin top last summer. It still looks great but it would be perfect had we done that.
Each project is different. Don't be afraid to change your technique. We have had great luck with rolling and tipping on other projects but it just didn't work well for us on the mast. But brushing alone did the trick. Gayle never tipped with a dry brush but I used it achieving the same results she did. So there's some wiggle room for individual technique. You must tip towards the paint you previously applied to keep a wet edge if you want to eliminate brush marks.
Most important. You must wear a good mask with the appropriate vapor cartridges when brushing any two part LPU paint no matter if you are inside or outside. Spraying the paint is an order of magnitude more dangerous than brushing because the paint is atomized. Though I have seen pro painters spraying with a mask and passive vapor cartridges all the manufacturers recommend a forced air mask with over pressurization to be safe when spraying.
We have several days of rain forecasted. In a couple days I'll start reinstalling the hardware. In the meantime, I'll start work on the boom which is at home in the garage along with the aluminum winch bases plates, spreaders, and the deck mast collar.
