• For semi-deep pour casting, filling, and molding applications
• Long working time for embedding items and complex pours
• High-gloss, crystal-clear finish; pour layers up to 2" deep in small castings
• Low-viscosity formula minimizes bubbles
• Designed for river tables, sculptures, live-edge slabs, bars, and more

TotalBoat ThickSet Epoxy is engineered for thicker coatings and deeper pours with extended working time to help reduce trapped air and heat buildup. Use for small castings up to 2" deep and coating builds up to 1/2" per layer. Tint with mica powders, alcohol inks, or pigment dispersions for custom effects.

Product Information

Cleaner / Surface Preparation

Denatured alcohol; acetone (only on compatible substrates).

Cleanup

• Part A — Resin: Denatured alcohol or acetone
• Part B — Hardener: Denatured alcohol
• Mixed (uncured): Scrape up excess; denatured alcohol, lacquer thinner, or acetone
• Cured: Remove mechanically

Thinner / Reducer

Do not thin this product.

Colorants / Tints

Use only epoxy-compatible dyes, inks, dispersions, or mica powders. Always test a small sample and allow to fully cure to confirm compatibility and effect.

Mold Release Agents

Use mold release paste wax or an epoxy-appropriate aerosol release for small castings.

Coverage

• Seal coat: ~24 sq. ft. per 1-gallon kit
• Flood coat @ 1/2": ~3.2 sq. ft. per 1-gallon kit
• ~3.25 sq. in. per 1 oz mixed epoxy @ 1/2" thickness
• Actual coverage varies with surface area, thickness, porosity, and waste

Safety & PPE

Always use proper PPE and follow the Safety Data Sheets for each component.

Exothermic Reaction Warning: Mixed epoxy left in a cup beyond working time can reach 200–300°F.

Surface Preparation

• Surfaces must be clean, dry, and free of oil, dust, moisture, lint, and sanding residue.
• Do not use paper towels or tack cloths; avoid touching with oily fingers.
• Sand as needed; remove residue; wipe with a clean, dry cotton rag dampened with denatured alcohol.

Wood & Other Porous Substrates (Seal Coat Required)

1. Apply a thin seal coat of mixed epoxy to a clean, dry, prepped surface. Fill knots or voids as needed.
2. Allow to cure hard; sand 80–120 grit to remove bubbles or imperfections.
3. Wipe clean with denatured alcohol using a clean cotton rag.
4. The seal coat creates an air-tight barrier to minimize off-gassing bubbles in the flood coat.

Application Conditions

• Maintain materials and workspace at 65–75°F and ≤60% RH throughout application and cure.
• Below 65°F, epoxy thickens, self-levels poorly, and traps bubbles.
• Above 75°F, epoxy sets too fast, increasing heat and risk of yellowing, distortion, or cracking.

Dispensing & Mixing

• Mix Ratio (by volume): 1A:1B
• Mix Ratio (by weight): 1.11A:1B
• Maximum mixing quantity: Only mix what you’ll use in approximately 20 minutes; do not mix more than 1 gallon at a time.

Mixing Technique

1. Combine resin and hardener; mix 3–5 minutes, scraping sides and bottom until uniform.
2. Transfer to a clean second container; mix 2–3 minutes more.
3. Stir slowly to avoid entraining air; let rest 1–2 minutes for bubbles to rise, then pour immediately.

Application

Coating Applications

• Do not pour thicker than 1/2" per coat.
• For thicker builds, pour multiple 1/2" layers at least 4 hours apart. Sanding is not required between layers.
• Exceeding 1/2" per coat can trap heat and cause waves, yellowing, or cracking.

Small Castings

• Maximum pour depth: up to 2" for small castings, up to 10 fl. oz. mixed epoxy per pour.
• For larger volumes, pour in multiple 1/2" layers, with at least 4 hours between layers.
• Tip: A pressure pot at approximately 50 psi can eliminate trapped bubbles in castings.

Working Time

• Pot life: ~10 minutes @ 70°F
• Total working time: ~30 minutes @ 70°F
• Pour out immediately after mixing to maximize working time.

Removing Bubbles

1. Allow 10 minutes after pouring for bubbles to rise.
2. Use a heat gun or propane torch 6–8" above the surface in a sweeping motion.
3. Avoid overheating; excess heat can mar the surface or move colorants.

Cure & Finish

• 1/2" coatings @ 70°F: Tack-free ~6–8 hrs; sandable ~24 hrs; light use ~48 hrs; full cure ~3–5 days.
• Castings: Demold after ≥24 hrs; support 3–5 days to prevent sagging as final cure completes.
• For best finish, allow full 5–7 days before wet sanding or buffing.
• For extreme UV exposure, apply a clear urethane or varnish topcoat.

Troubleshooting

Bubbles

Keep room and materials within the recommended range, 65–75°F, use a seal coat on porous wood, and pour in thin layers to aid bubble release.

Fisheyes

Most often caused by surface contamination. Small fisheyes can be filled with TotalBoat TotalBond or a clear UV-cure resin such as TotalBoat UV Cure Clear Resin. Ensure repair materials are fully cured and sanded to approximately 220 grit before recoating.

Surface Imperfections

1. Allow approximately 24 hours to reach a sandable state.
2. Spot-sand with 120–220 grit; clean; fill defects with TotalBoat ThickSet Epoxy or use TotalBond / UV Cure Clear Resin for tiny voids.
3. Lightly sand overall and recoat evenly.

Incomplete Cure

Verify 1:1 by volume or 1.11:1 by weight ratio, thorough two-cup mixing, and ambient temperature at or above 65°F. Do not scrape the original mix cup onto the surface because unmixed residue can create sticky spots.

Crystallization

If resin appears cloudy, grainy, or solid, warm the sealed bottle in a 125–140°F water bath, agitating periodically until clear. After returning to ambient temperature, the epoxy can be used normally.

Product Storage & Shelf Life

• Store 60–90°F, dry, tightly sealed; maintain consistent temperature. Do not allow freezing.
• Keep off cold floors and away from exterior doors or walls in winter.
• Shelf life: Minimum 1 year, typically longer if stored properly.

Application Data

Physical Data