TotalBoat
ThickSet Cast + Coat Deep Pour Epoxy
- Type
- Casting
- Data sheet revision
- February 24, 2025
- Sources checked
- 2026-09-30
- Page status
- Published October 3, 2026
A 1:1 cast-and-coat epoxy. TotalBoat's data sheet allows up to 1/2 in per coat for coatings and up to 2 in for small castings, with at least 4 hours between coats at 70 °F.
Published values
Copied as printed, with test conditions where the manufacturer gives them. Tags link to the source document.
| Mix ratio by volume (A:B) | 1A:1B by volumeTDS |
|---|---|
| Mix ratio by weight (A:B) | 1.11A:1B by weightTDS |
| Maximum pour depth per layer | Up to ½" per coat (coatings); up to 2" (castings up to 10 fl. oz.)TDS2 in only for small castings using at most 10 fl oz of mixed epoxy; coatings, river tables and slab pours: ½ in per coat/layer. |
|---|---|
| Minimum pour depth | not published |
| Maximum mass or volume per pour | maximum of 10 fluid ounces of mixed epoxy for 2" castingsTDSsmall castings poured at the 2 in maximum depth; separately, TDS advises not mixing more than one gallon at a time |
| Recommended temperature | 65-75°FTDSmaterials and workspace during the whole application and cure; 0-60% RH; optimal 70°F and <60% RH |
| Pot life | 10 minutes at 70°FTDSat 70°F |
|---|---|
| Gel time (lab mass) | 70 minutes (150 g mass)TDSat 77°F, 150 g mass |
| Working time | 30 minutes at 70°FTDSat 70°F |
| Time between pours | 4 hours minimum at 70°F — no sanding requiredTDScure time between coats/layers of ½ in or less, at 70°F |
| Recoat window | not published |
| Tack-free | 6-8 hoursTDScoating applied at ½ in thickness at 70°F |
| Demold | minimum 24 hours before demoldingTDScastings |
| Full cure | 3-5 days (at 65-75°F)TDSat 65-75°F |
| Mixed viscosity | 1,500 (+/-500) cP at 77°FTDSat 77°F, tolerance +/-500 cP |
|---|---|
| Specific gravity or density, Part A | 1.15 g/cm³ at 77°F (published as Resin Density)TDSpublished as density of Part A (resin) in g/cm³ at 77°F, not labelled specific gravity |
| Specific gravity or density, Part B | 1.03 g/cm³ at 77°F (published as Hardener Density)TDSpublished as density of Part B (hardener) in g/cm³ at 77°F, not labelled specific gravity |
| Specific gravity, mixed | not published |
| Density, mixed | not published |
| Hardness | 78 (+/- 5) Shore DTDS |
What the numbers mean for a pour
Pours needed with a limit of 1/2 in per pour, the strictest of the limits the documents give. Worked out with the layer planner.
| Total thickness | Pours | Earliest start of last pour | Notes |
|---|---|---|---|
| 1 in (25 mm) | 2 | 4 h after the first, if the conditions below are met | – |
| 2 in (51 mm) | 4 | 12 h after the first, if the conditions below are met | – |
| 3 in (76 mm) | 6 | 20 h after the first, if the conditions below are met | – |
| 4 in (102 mm) | 8 | 28 h after the first, if the conditions below are met | – |
Only if these published conditions are met: cure time between coats/layers of ½ in or less, at 70°F
What the manufacturer says
Paraphrased from the manufacturer’s documents.
Heat
- Mixed epoxy left in the cup past its working time can heat to 200-300°F while curing.TDS
- Items hotter than 122°F should not be placed on the cured surface.Page
Other notes
- The TDS advises against mixing more than one gallon of epoxy at a time.TDS
- The TDS gives a gel time of 70 minutes for a 150 g mass at 77°F.TDS
- Cured density is published as 1.08 g/cm³ (ASTM 792); this is the cured solid, not the mixed liquid.TDS
- Demolded castings may need support for 3-5 days because they can sag until fully cured.TDS
- The product page advises working in a well-ventilated area with gloves, eye, face and clothing protection.Page
Temperature
- Working above 75°F can make ThickSet set too quickly and overheat.TDS
- If the epoxy was below 65°F while setting up, warming the space to 80-90°F for 12-24 hours can help it reach full hardness.TDS
Layering
- Build coatings thicker than ½ in from layers of ½ in or less, at least 4 hours apart, with no sanding needed between coats.TDS
Surface preparation
- Wood and other porous surfaces always need a seal coat before the flood coat.TDS
Coverage
- A 1-gallon kit yields 231 in³, covering 462 in² at ½ in thick, not counting waste.TDS
UV and color
- Pieces facing extreme UV exposure should be top-coated with clear urethane or varnish to prevent yellowing.TDS
Where the manufacturer’s documents disagree
- Pot life: 10 Minutes at 70°F (TDS) vs. Pot Life @ 77°F: 10 minutes (product page) (TDS, Page). The table shows the value from the TDS.
- Working time: 30 minutes at 70°F (TDS) vs. 30 minutes @ 77°F (product page) (TDS, Page). The table shows the value from the TDS.
- Tack-free: 6-8 hours at ½" thickness, 70°F (TDS) vs. 4-8 hours for 1/2" pours at 77°F (product page FAQ) (TDS, Page). The table shows the value from the TDS.
- Recommended temperature: 65-75°F (TDS; product page spec line 65°F-75°F) vs. ambient temperature must be between 65°F and 80°F (product page IMPORTANT note) (TDS, Page). The table shows the value from the TDS.
- Maximum pour depth per layer: Up to ½" per coat (coatings) / up to 2" (castings up to 10 fl. oz.) (TDS) vs. for slabs or tables do not exceed a pour depth of ½" to 1" (product page FAQ) (TDS, Page). The table shows the value from the TDS.
Not published
The documents listed below give no value for: Minimum pour depth; Recoat window; Specific gravity, mixed; Density, mixed. We leave these blank rather than estimate them.
Use this product in a calculator
Sources
- TotalBoat. TOTALBOAT THICKSET EPOXY (TDS). Document revision: February 24, 2025. Accessed September 30, 2026.
- TotalBoat. ThickSet Cast + Coat Deep Pour Epoxy Resin Kits (Page). Accessed September 30, 2026.