[strick]

I've sprayed two boats with it inside and out...I never did all the figuring you have done though. I cant even remember how much paid for the stuff....or how much it took to cover the boat. I have a commercial account with a local boat shop so I get a good deal. If you have a big boat yard near you that sells it then you may find a better deal on your materials so check around and tell them you have a boat restoration business and you want to open a commercial account.

for a 20sf I would start with 2 quarts primer and 2 quarts converter as this gives you a gallon of material. Then get one quart of out side paint plus one quart inside paint plus the respective converters. A little of the paint goes a long way. Is the hull bottom going to be a different color then the hull sides?

I would not recommend spraying Awlgrip out side. You don't need to be in a booth but you do need to be in a somewhat controlled environment. You need good lighting as well. How good you prep the boat with your sanding and fairing compounds will will determine how much primer you use...but 4 good heavy coats of primer is a good estimate. The primer does not spray as easily as the paint does...it's a little thicker. It dries very fast and spray technique is not all that important...just get it on the boat. The paint is misted on the first two coats and allowed to flash then successive heavy coats are applied...till it looks good. I don't know what experience you have with a spray gun... I was trained in my early teens how to spray clear lacquer on kitchen cabinets when I was a painter. You have to keep moving all the time. Try practicing on something first and you will get the hang of it...its really not that hard. Awlgrip is one hell of a tough paint...and it looks great!

Make sure you have lots of ventilation...full tyvec suite...best respirator money can buy goggles and a hood.

strick