Wear gloves, safety glasses, and protective clothing to avoid skin and eye contact.
Avoid eating, drinking, or smoking when handling epoxy.
Prepare the Surface:
The surface should be dry, clean, and free of dust, oil, or contaminants.
If the surface is porous (like wood), consider using a seal coat of a thin epoxy to prevent air bubbles during the deep pour.
Measure & Mix:
Measure out the epoxy and hardener in the ratio specified (for 2:1, that's 2 parts epoxy to 1 part hardener by volume).
Pour the hardener into the epoxy (not the other way around).
Mix thoroughly for at least 5 minutes. Ensure you scrape the sides and bottom of your mixing container. Be careful not to whip too much air into the mixture.
Pour the mixed epoxy slowly into your mold or the area you want to fill.
For deep pours, you might want to pour in layers to avoid overheating and excessive bubbles. Check the manufacturer's guidelines on the maximum recommended thickness for a single pour.
Remove Air Bubbles:
After pouring, you might notice air bubbles. These can be removed by using a heat gun or propane torch. Gently sweep across the surface to pop the bubbles. Be cautious not to burn the epoxy or stay in one place too long.
Allow the epoxy to cure based on the manufacturer's recommended time. This can vary, but many deep pour epoxies can take 24-72 hours for an initial cure and up to a week for a full cure.
The curing process is exothermic, meaning it releases heat. Avoid touching the surface during curing, as it can get quite hot.
Demolding and Finishing:
If you've used a mold, once the epoxy has sufficiently cured, you can remove it from the mold.
You can then sand, polish, or finish the epoxy surface as desired.
Uncured epoxy can be cleaned with acetone or isopropyl alcohol.
Cured epoxy can be mechanically removed (sanding, scraping).