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Hi, 1. Make sure you are reducing the paint exactly as indicated on the can label. Also the correct hardener ratio.
2. Make sure you have stirred the mixed paint well and strained it through a paint strainer before putting it into the gun cup.
3. Make sure your gun is absolutely squeeky clean inside, particularly the fluid tip orifice, and that there is no buildup on the fluid needle. Also verify cleanliness in the air cap orifices.
4. Make sure the packing nut around the fluid needle is not too tight or too loose. If it's an old gun, the packing may need to be replaced. A light lubrication of this packing would also be in order.
5. Make sure you have a good seal between the fluid tip and body. There probably is some kind of gasket there. If the gun is old and has been disassembled a lot, this gasket may need to be replaced.
6. Make sure you are using the proper atomizing air pressure and measuring it correctly. If the gun is HVLP, the pressure should be stated in the instructions that came with the gun or, better yet, engraved on the gun body. If it is conventional, the pressure for that type of paint is typically between 40 and 60 psig. All pressures should be measured at the gun inlet with the trigger pulled.
7. Always verify a properly shaped and even pattern distribution by a trial application on a piece of cardbord using a rapid trigger pull and release. There is no point in proceeding to paint until a good pattern is observed in this fashion. Various pattern problems and how to correct them should be described in the instructions that came with the gun. If you don't have that, some information from DeVilbiss, which is pretty generic, is available here.  Rod
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