Dan Man,
Sounds like you have tackled this from all angles. It was interesting to read what you are trying. As a matter of interest, how long do you allow for the paint to dry between coats. I wonder about using methylated spirits as it can leave a film. I seem to remember this when using it to clean windows. I used a rag with turps. Maybe it would be better to just use a damp cloth and wait for the gun to dry.
This is probably like telling you to suck eggs, but for the benefit of those who are tackling this for the first time, I've been using a marine varnish and notice that you require about 24 hours between coats and longer in colder weather. I coat one side, allow it to dry overnight then turn it over and coat the other side. After a further twelve hours it is back to the origin side. It is a time consuming job. It is recommended you apply four coats.
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