How to Fix Spray Gun Mistakes on Your Car: Troubleshooting Orange Peel, Runs, and Uneven Coats

So, you finally got your hands on a spray gun, set up your workspace, and went all in on giving your car a fresh coat of paint. But instead of that sleek, mirror-like finish, you ended up with orange peel, paint runs, or patchy, uneven coverage. 

Sound familiar? Don’t worry—you’re not alone. Even seasoned pros run into these issues from time to time.

The good news? Most spray gun mistakes are fixable, and with the right techniques, you can turn that “oops” into a flawless finish. 

1. Orange Peel: When Your Paint Looks Like a Citrus Fruit

Orange peel happens when the paint surface ends up with a textured, bumpy look instead of a smooth, glass-like finish. The main culprits?

• Incorrect Spray Gun Settings: Too much air pressure or the wrong fluid tip size can cause poor atomization.
• Improper Paint Viscosity: If the paint is too thick, it won’t level out properly.
• Spraying Too Close or Too Far: Holding the spray gun too close lays down excessive paint while spraying too far leads to poor atomization.
• Environmental Factors: High humidity or cold temperatures can mess with paint flow and drying.

How to Fix It

1. Wet Sanding & Buffing. Once the paint has fully cured, use 1,500 to 2,500-grit sandpaper to wet sand the surface, then buff it out with a polishing compound to restore the shine.
2. Adjust Your Spray Gun Settings. Make sure your air pressure is within the recommended range. If needed, refer to resources like SprayGunner.com to find the best setup for your specific gun model.
3. Thin Your Paint Properly. Follow the manufacturer’s recommendations for paint-to-thinner ratios to ensure proper flow and atomization.
4. Maintain Proper Distance. Keep the spray gun about 6-8 inches from the surface and move at a steady pace.

2. Paint Runs and Sags: When Gravity Isn’t Your Friend

Paint runs happen when too much paint builds up in one area and starts to drip or sag. Common reasons include:

• Applying Too Much Paint at Once: A heavy coat increases the chance of runs.
• Holding the Spray Gun Too Close: Spraying too close concentrates paint in one area instead of evenly distributing it.
• Incorrect Gun Angle or Speed: Moving too slowly or angling the gun too much in one direction can lead to buildup.

How to Fix It

1. Let It Dry and Sand It Down. Don’t try to wipe it off while it’s wet. Let the paint fully cure, then use fine-grit sandpaper (1,500-2,000 grit) to level the surface before applying another light coat.
2. Spray in Lighter Coats. Instead of one heavy pass, apply multiple thin layers to build up the coverage without drips.
3. Use the Right Technique. Keep your strokes consistent, overlapping each pass by 50% for even distribution.

3. Uneven Coats and Patchy Coverage

Uneven paint coverage happens when some areas have too much paint while others barely have any. Causes include:

• Inconsistent Spray Gun Movement: Moving too fast or too slow can create patchy areas.
• Incorrect Overlap Technique: Not overlapping spray passes correctly leaves gaps.
• Improper Air Pressure or Fan Pattern: Poor atomization leads to an uneven finish.

How to Fix It

1. Apply Even, Overlapping Strokes. For consistent coverage, each pass should overlap the previous one by about 50%.
2. Check Your Spray Pattern. Before starting, test your gun on a scrap piece to ensure it sprays evenly.
3. Adjust Your Air Pressure. Too low and the paint won’t atomize properly; too high and you’ll waste paint with excessive overspray.

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4. Fish Eyes: When Your Paint Surface Looks Like It’s Breaking Out

Fish eyes are small craters or dimples in the paint surface, often caused by:

• Contaminants on the Surface: Oil, silicone, or grease residues can prevent paint from adhering properly.
• Using the Wrong Cleaner: Some cleaning products leave behind residues that interfere with paint adhesion.
• Mixing Paint with Dirty Equipment: A spray gun that hasn’t been properly cleaned can introduce contaminants.

How to Fix It

1. Strip and Repaint. If fish eyes appear, you’ll need to sand down the affected area, clean it thoroughly, and repaint it.
2. Use a Wax and Grease Remover. Before painting, wipe down the surface with a proper degreaser to eliminate any contamination.
3. Ensure Your Spray Gun is Clean. Disassemble and clean your spray gun after every use to prevent leftover contaminants from ruining future paint jobs.

5. Dry Spray: When Your Paint Looks Chalky and Dull

Dry spray happens when the paint particles dry before they even hit the surface, creating a rough, dull appearance. Causes include:

• Spraying in Hot or Windy Conditions: High temperatures or wind can cause the paint to dry too fast.
• Holding the Gun Too Far Away: Spraying from too far reduces paint adhesion and smoothness.
• Low Paint Flow Settings: Not enough paint reaching the surface can result in a dry finish.

How to Fix It

1. Sand and Recoat. Lightly sand the area with 1,500-grit sandpaper, then apply a fresh, wet coat.
2. Spray in the Right Conditions. Ideal painting conditions are 65-75°F with low humidity.
3. Adjust Your Spray Distance. For best results, keep the gun consistently 6-8 inches from the surface.

Final Thoughts

Nobody gets a perfect paint job on the first try mistakes happen! But the key is knowing how to troubleshoot and fix them. If you’re dealing with orange peel, paint runs, or patchy coverage, patience and the right techniques will get you back on track.

If you’re serious about improving your spray gun skills, take the time to experiment with different settings, practice on test panels, and always prep your surface correctly.