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After leaving the armour in an open, well-ventilated place at room temperature, with no humidity, one would expect the painted armour to have dried/hardened by now. To my surprise, and the confusion of the "experts" who sold me the paint, this was not the case. My parents helped me wrap all 384 sticky pieces of armour in wax paper, as I had to return to Thunder Bay with the armour to finish the suit, and didn't want them sticking to each other.
Some of their theories included the adhesion promoter reacting with the paint or the plastic, or perhaps the water-born paint just takes longer to dry.
I returned to Thunder Bay, and spoke with the original people who suggested the 3-stage paint. I told them I used a single-stage urethane, and immediately they knew the problem.
IMPORTANT: If you use a single-stage urethane, and the manufacturer doesn't INCLUDE A HARDNER in the can, the paint will NEVER dry. Evidently, there is supposed to be a pin on the bottom of the can that you pull, which allows the paint to mix with the hardner, PRIOR to spraying the last 8 months of work with.
My only option - clean each piece of plastic by hand, and repaint. Yep. FML.
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