Hi John, I am not Butch but I generally agree with his posts on this forum. In any event, I'll take a crack at your questions with your stated limitations. For cast only: 1.Forget phosphoric acid treatment 2.Forget etch primer (has a phosphoric acid component) 3.Power wash 4.Chemically strip all paint 5.Wire brush to as rust-free a surface as possible - shouldn't be too hard on the cast 6.Clean with specialized cleaner such as PPG DX330, Acryli-Clean 7.Prime immendiately with two part epoxy primer such as PPG OMNI MP170 8.Set aside until you are ready to color coat 9.When you are ready to color coat, clean again with the 330, scuff the epoxy with a coarse ScotchBrite pad and apply another coat of epoxy. The pad makes it generally fairly easy to get into odd areas that would be more difficult with sandpaper. You can also get the pads in small 2" and 3" discs that you can use in an electric drill or die grinder 10.Topcoat within the epoxy window (3 days for MP170 only) 11.Generally forget bondo on cast - not sure of your intent there Since you wish to avoid isocyanates with no fresh air breathing equipment (good decision, btw) you are pretty much limited to enamels without hardeners. That leaves the synthetic enamels like most tractor store paints are and the acrylic enamels that are used in low-end automotive refinish work. The acrylic enamels will be a little better durability than the synthetics and are also somewhat more expensive. Two major lines of automotive acrylics are PPG's OMNI MAE acrylic enamel and DuPont's NASON Fast-Dry acrylic enamel. Both of these paints can be used w/o the hardener. Just be aware of the downsides of not using a hardener - see a previous post of mine for my opinions on this. You might also be able to get a higher-end acrylic enamel in DuPont's Centari or PPG's Delstar but they may or may not be available in your area and they may or may not be available in the specialized tractor color formulations. Either can be used w/o hardener. They definitely would be more expensive than the OMNI or NASON choices. Rod
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