Thank you gentlemen for the explanations. I am aware of the "blush" reside from epoxy. As I mentioned I am varnishing two kayaks built exactly the same way, one is fine the other is a problem. I use West epoxy with fast hardener. I seal the wood then apply the cloth 3 hrs. later. I start applying fill coats 3-4 hrs apart for 3 total fill coats. I apply the fill with a flexible scraper then go over it with a foam roller to disperse the small ridges left by the scraper then a foam brush to pop the bubbles left by the roller. From seal coat to final fill coat is approx. 14-15 hrs. My shop thermostat is set at 72 degrees and I have hot water heat so I can preheat the epoxy by setting it on the 1" copper pipes going to the furnace.

If blush is my problem then I am sanding off the varnish, cleaning and revarnishing but I thought my method of application would eliminate blush as a potential problem by never giving it a chance to form. I am still at the point of knowing I have a problem that needs to be corrected but no idea why I have the problem especially when I did both kayaks exactly the same way :((((