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URO primer/filler can be sprayed directly over bare metal. I prefer to shoot a coat of self-etching primer first, like Vari Primer. Do not apply more URO than necassary. It costs too much to waste and just as you said, applied too thick can cause nicks if bumped very hard. The primary purpose of these high fill/high solids primers is to allow faster build up on uneven surfaces. It would take days for laquer primer to be built up, dry and be sanded level on very uneven surfaces. Epoxy primers allow you do to the same thing in a matter of hours, or minutes. But as with anything that saves time, it costs money. You might try Dupont's other brand called Nason. It is compatable with all other Dupont products and costs considerabley less. I have had good luck with Marhyde epoxy primer as well as Timberline. I prefer Timberline simpley because it is the same cost as the Nason but has more solids therfore builds faster with less waste. How do you know if a product has more solids? Simple. Weigh a gallon of each and see which weighs more. If you do this you will find Timberline to be the heaviest of any of the "bargain" brands. You probably won't even need a scale to do this. Just pick up one and then the other. The difference should be very noticable. PS. your spray gun should be capable of handing high solids as they spray thicker and require a larger fluid tip. This is where primer guns earn their keep. They have larger fluid tips to deliver thick liquids efficently with little or no overspray and no waste. A gravity feed HVLP is hard to beat in this application.
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