[May70]

Are you saying the top coat material was too thick and laid out tar like? That's not a problem with the substrate, that's a problem with the top coat or the application of the topcoat. If its that thick it either needs to be thinned or thrown out. Old can? If so id trash it. Not familiar with the TDS, what does the TDS say? Can you thin it and by what/%? Sounds like an old can possibly that you then put too much thinner in or possibly NIAW the TDS. Letting paint in the can or after application (before cured) get too cold can ruin it.

I have seen several failed POR jobs. I think its great stuff when used to pretty up something, as long as its applied over knocked down rust. Issues I have seen too many times come from using it on fully prepped metal. Many people use it without issue but the few that have issues I know of, it screwed them to the point they had to go to bare metal and restart.

At this point I would let it fully cure, then feather all the rough spots out here you tried to remove the topcoat. I'm sure that probably doesn't look too good. With the material you have on it now, id scuff the rest and use a sealer/topcoat of another product. Or risk trying to topcoat it with what you have IF you can get the consistency right on a test piece. I wouldn't spray POR. If you cant get it to feather out, id have it blasted and just go with a sealer/single stage topcoat

I'm no painter but I've had my share of bad experiences. GL man! Paint issues suck, maybe try the paint/body section folks.