My understanding of the phosphoric acid and epoxy problem is getting the acid neutralized. The key is reapplying the phosphor to the the panel and then washing it off with water while its still wet. I live 2 miles from the beach and don't understand what all the rust fuss is about. After applying phosphor to my bare panels and washing it off with a hose or even a pressure washer when done (while still wet or if time got in the way reapplied days later to reactivate the acid) I simply blew the panels dry with a shop vac and found I could let them sit for a week or more with no problems at all. Occasionally a very light flash rust appears but that comes off with a light sanding. I then hit the panel with a wax and grease remover let it sit for a min of 30 minutes and then spray my epoxy. The key there is making sure everything has a chance to evaporate out of the pores of the metal before sealing with the epoxy... just my .02 good luck with your project.
Last edited by CASO; 08/16/2011 10:17 PM.
