Hello Ken:

Again pardon me for sounding like a DF rookie but you mentioned that you had UV inhibitors in your epoxy as well as the poly resin. I am not familiar with these UV resistant types or the clear (not green, red, or blue) poly resin. Some questions: What type of epoxy are you using? What is the name of the poly resin and wax/styrene additives that were used? Thirdly, if the poly resin is harder and more durable than the underlying epoxy, why not eliminate the epoxy from the whole equation and the required pure mechanical bond between the two and just build up an extra fill coat or two of the substituted poly resin before sanding/finishing?

It's unfortunate the experiment wasn't sucessful. Shows a lot of promise though for the more experienced builders like yourself if the bugs can be worked out.

Mark