[dmjlambert]

The way I used POR15 was to: do the cleaning and metal prep steps, then brush on the POR15. It only takes 1 coat. It is a thin paint. Let it get mostly dry but still a little bit tacky and then give it a light mist of spray on primer. Then let it dry completely a couple of days. The more humid the environment is, the faster it dries. If it is not humid at all and air is very dry it could take some days to dry.

Then do whatever other stuff to it such as put on a full primer coat and regular paint. What is this tar to thick latex paint consistency top coat are you mention? Is that something else by POR15, the same POR15 paint that went on before except now it is thick for some reason, or some other product? It seems whatever you are using for the top coat may be old or has some sort of problem.