Correcting Second Coat Failure (Sanding & Cleaning)
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A bad Epoxy Job on Our DIY Live Edge Kitchen countertop ... how to do Epoxy repair Pt3
What happens here
The second epoxy coat experienced a severe exothermic reaction during mixing, heating to 235°F (112°C) in the bucket and resulting in an uneven, rippled surface on the countertops ('alligatoring'). To rectify this, the failed epoxy layer must be completely sanded off. Begin with an 80-grit sandpaper using a random orbital sander (Milwaukee M18) for aggressive removal, then progress through finer grits such as 120, 220, 400, and finally 600. Between each grit change, the surface is meticulously wiped down with isopropyl alcohol and a clean white cloth to remove all sanding dust and residue. This is a labor-intensive process, described as 'nasty' due to the mess created.
Goal: Remove the failed, uneven epoxy layer and prepare the surface for a successful final application
Tools and materials
- Clean white cloth — Wiping the surface with isopropyl alcohol
- Infrared Thermometer Extech IR250 — Measuring the temperature of the epoxy during mixing to detect exothermic reactions
- Random Orbital Sander Milwaukee M18 — Aggressively removing the failed epoxy and smoothing the surface
- Sandpaper — Sanding the epoxy (80-grit for aggressive removal, up to 600-grit for fine finishing)
- Isopropyl Alcohol Good Sense — Cleaning the surface between sanding stages
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