Pouring epoxy and stopping a surprise leak

So, your mold is ready to pour epoxy? In this blog we are going to make sure we calculate the proper amount of epoxy is mixed properly and learn how to fix a surprise leak! The links are affiliate links so I do receive compensation if you purchase from that link. Any amount of help helps a small business like mine!

Mold Release

An incredibly important step is to spray your form with mold release. If you forget to do this, it will create hours of work trying to get that melamine off. Take the mold release and spray the entire form very well. After a few minutes, use a clean rag to buff it in. Spraying in a different pattern, coat the entire form very well again. After a few more minutes, buff it again.

Calculate Epoxy Volume

Place your slab into the form. I did not do any surfacing to my slab before doing this. I follow the rule, keep the slab as thick as possible for as long as possible. You do need to use more epoxy, but it will give you wiggle room in the long run if you need to remove more material.

Measure the distance between two slabs. Start at one end and work your way to the other end. I take a measurement every couple of inches. The more measurements you take, the more accurate you are going to be. Use a crayon or chalk to write the number on the slab itself so you can keep track. Once you make it to the far end, add all the measurements up. Divide that number by the number of measurements you took. This gives you width. The height is the tallest point of the slab. The length is the length of your form.

While you can do this math yourself if you wish, using an epoxy calculator is much easier. Make sure to set the volume unit to US Gal, unless you are using some over form of volume. I like this volume calculator Powered by Omni Calculator. You can also use it on their website HERE.

Picking your Epoxy

There are many different types and brands of epoxy. It is important to select the proper epoxy for the application you are wanting it for. You can’t use a tabletop epoxy for a deep pour application. For deep pour applications, I use Liquid Glass epoxy.

Seal Coat

Before mixing all your epoxy, make a smaller batch to make a seal coat. This is primarily important if you are using dye to color your epoxy. The dye’s can stain your wood and can sometimes be impossible to remove. A seal coat will also help reduce bubbles forming on the edges of your slab. Use a paint brush to brush epoxy onto the edges and top of your slab.

Mixing Epoxy

Mixing epoxy is the most critical step of the entire process. We can fix every problem in the process, except improperly mixed epoxy. If it is not mixed properly, it will not cure and can ruin the table. Fortunately, mixing epoxy is easy. The only way this can go wrong is by being lazy.

Follow the provided direction strictly. For Liquid Glass, mix it for 5-8 minutes. It takes hours before the exothermic reaction begins so there is no rush. MAKE SURE IT IS MIXED VERY WELL. Using a drill attachment will make your life much easier. From time to time, use a paint stirrer to scrape the sides and bottom.

You can also mix in a dye or pigment to color the epoxy. To ensure the color’s stay consistent between each bucket of epoxy, use a measuring spoon to get the exact amount in each bucket. For a liquid dye, count the drops.

Pouring Epoxy

Epoxy will find every crevice and self-level itself. You do not need to spread the epoxy around; it will do that all on its own. Trying to spread it yourself will just introduce bubbles. Just pour in a single spot, slowly and controlled. This will put you in the best position for the least number of bubbles. For any bubbles that rise to the surface, use a torch or a heat gun to pop them.

Make sure you pour your epoxy in a temperature-controlled environment, or during a time you know the weather will be consistent for a few days in a row.

Surprise leak!

So now that a few buckets are in, you have identified a leak in one of your seams. Don’t sweat it. No matter how bullet proof you try to make your form, epoxy is a finicky beast and will find any way out it can. Flex Seal Paste is a life saver in this situation. Don’t be sparing with it, spread a ton on the affected area to ensure it has no way out.

Congratulations, now it’s time to wait for your epoxy to cure! In the next blog post we will talk about demolding and flattening your slab!