Avoid These 12 Epoxy Pour Mistakes

Epoxy resin can transform live-edge wood into a stunning river table, countertop, or art piece—but it's also unforgiving. One wrong move can lead to cloudy finishes, sticky surfaces, or expensive do-overs.

At Fusion Wood Creations, we've poured thousands of litres of resin into custom furniture. Along the way, we've seen (and fixed) a lot of mistakes. This guide breaks down the 12 most common epoxy pour mistakes that we have encountered, how to spot them, and the proven fixes we use in our shop.

Whether you're a DIY hobbyist or commissioning a custom table, this list will help you avoid costly errors and get flawless results.

1. Pouring Too Thick at Once

The mistake: Trying to pour a deep river table in one go.

What happens: Resin overheats, cracks, or refuses to cure.

Fix: Pour in controlled layers. For deep pours, use a resin formulated for thickness (often labeled “deep-pour epoxy”), and keep each layer within the manufacturer's guidelines.

2. Not Sealing the Wood First

The mistake: Pouring resin directly onto raw wood.

What happens: Air escapes from the grain, causing endless bubbles.

Fix: Apply a thin “seal coat” of resin to the edges of the wood using a brush or spreader. Allow it to cure until it's tacky; if it fully hardens, lightly sand the surface to promote adhesion for your main pour. This step traps air pockets and helps achieve a crystal-clear finish.

3. Mixing the Wrong Ratio of Resin and Hardener

The mistake: Eyeballing the mix or using volume when the brand requires weight.

What happens: Soft, sticky, or uncured epoxy that never hardens or the resin could overheat and flash cure.

Fix: Always measure precisely according to the manufacturer's instructions. Use a digital scale if required. Scrape the sides of your mixing container—but don't overwhip air in.

Epoxy resin is too expensive to waste; it's worth spending an extra 10-15 minutes measuring accurately to ensure the right quantities.

4. Pouring in the Wrong Temperature

The mistake: Working in a cold garage or hot workshop.

What happens: In cold conditions, resin thickens, traps bubbles, and cures slowly. In heat, it accelerates and cracks.

Fix: Keep your workspace between 21–27°C (70–80°F) unless the resin label says otherwise. Warm resin bottles slightly in hot water if they're too viscous or if they have become cloudy or lumpy from being stored.

5. Skipping Proper Mixing

The mistake: Stirring too quickly or not long enough.

What happens: Streaks, cloudy patches, or soft spots in the cured resin.

Fix: Mix slowly for at least 3–5 minutes. Scrape the bottom and sides of the cup. Transfer to a second cup (“double-cup method”) and stir again for best results.

6. Ignoring Dust and Debris

The mistake: Pouring in a dusty shop or leaving your project uncovered.

What happens: Floating sawdust, hairs, and lint permanently embedded in your finish.

Fix: Wipe surfaces with a tack cloth, use a dust-free tent or plastic sheeting, and cover your project while it cures.

7. Forgetting to Torch or Heat Gun the Surface

The mistake: Assuming bubbles will disappear on their own.

What happens: Cloudy or foamy epoxy, especially in deep pours.

Fix: After pouring, gently sweep a propane torch or heat gun over the surface to release any trapped bubbles. Repeat this process every 5–10 minutes during the first half hour of curing, then continue monitoring until the resin reaches the B-stage. This is why timing your pours is so important—otherwise, you may find yourself waking up at 3 a.m. just to chase bubbles!

8. Using the Wrong Mold or Form

The mistake: Pouring into untreated wood boxes, MDF, or cardboard.

What happens: Resin sticks permanently or leaks out.

Fix: Always use a Mold lined with HDPE, melamine sealed with tape, or silicone. Apply Mold release spray for easy demoulding.

9. Not Accounting for Resin Shrinkage

The mistake: Filling a form exactly to the top.

What happens: A shallow dip appears once the epoxy shrinks during cure.

Fix: Overfill slightly, always ensure the resin is poured proud of the wood, then sand and polish flush once cured. Alternatively, add a thin flood coat after the main cure.

10. Rushing Sanding and Polishing

The mistake: Jumping from coarse grit straight to polishing compound.

What happens: Hazy finishes that never achieve true glass clarity.

Fix: Work through progressive grits (80 → 5000+). Wet sand from 400 upwards, then polish with a buffing compound. We use 3M Perfect-it Fast Cut Plus, Extra Fine Plus and Ultrafine SE for that mirror effect finish and although it's more expensive than others on the market – it's worth the investment (links below)  

Spending a little more on high-quality finishing tools is an investment that pays off in both results and efficiency. Cheaper alternatives may seem appealing at first, but they often wear out quickly, clog easily, and deliver inconsistent finishes—meaning you'll spend more time, more effort, and often more money in the long run.

At Fusion Wood Creations, we rely on trusted professional-grade brands such as Mirka (Abranet and Abralon) and 3M (Trizact).  These brands are known for their durability, consistent performance, and innovative designs that make sanding and polishing smoother and more precise.

https://www.3m.co.uk/3m/3n_GB/p/d/b40065594

https://www.3m.co.uk/3M/en_GB/p/d/b5005010001/

https://www.3m.co.uk/3M/en_GB/p/d/b40071685/

 

11. Forgetting About UV Protection

The mistake: Using any epoxy indoors or outdoors without checking its UV resistance.

What happens: Yellowing, fading, and loss of clarity.

Fix: Choose a resin with built-in UV inhibitors and, for outdoor furniture, finish with a topcoat that has extra UV resistance.

12. Not Planning Enough Resin

The mistake: Running out of resin mid-pour.

What happens: Layer lines, incomplete fills, uneven hardness and colour inconsistencies.

Fix: Use an online resin calculator before mixing. Always buy at least 10–15% extra than your calculation—cheaper than reordering and re-pouring later.

Bonus Tip: Practice on Small Projects First

Before tackling a full dining table, test your process with coasters, trays, or side tables. Small mistakes are cheaper to fix, and you'll build the muscle memory for flawless pours.

FAQs

Q: Can I fix sticky epoxy after it cures?
A: If it's only tacky on top, sand off the layer and apply a fresh flood coat. If the mix ratio was wrong, you may need to remove the resin completely and start again.

Q: Why is my epoxy cloudy?
A: Cloudiness usually comes from moisture, cold temperatures, or improper mixing. Warm your workspace, mix thoroughly, and seal porous wood before pouring.

Q: How thick can I pour epoxy in one layer?
A: Depends on the brand. Some deep-pour epoxies allow up to 10cm's, but most standard resins should stay under 2-5cm's per layer.

Conclusion

Epoxy resin is equal parts science and art. The good news? Every mistake on this list is avoidable with the right preparation.

At Fusion Wood Creations, we specialise in custom epoxy river tables, live-edge designs and furniture that are built to last. If you'd rather skip the trial-and-error (and wasted resin), let us build your dream piece for you. Visit our Design Your Own page to create a custom river table, or browse the unique pieces we've already crafted, which are ready to ship here.