I was getting tired of using the 400 grit before the flow coat so I went to 220 wet, man that was a bad idea... I ended up going all the way to the sealer. The burn through is about 4"x1".

Well anyways, here's what I plan on doing, please correct me if I'm wrong or any tips. I don't think I'll have trouble blending in the clearcoat because I still have to do the flow coat, the problem is blending the metallic properly.

1. Feather edge the burn area.
2. Spray 1 coat of sealer a little past the burn area, sand to 600 grit.
3. Spray 1 coat of intercoat clear in the surrounding area (about a 1' further out).
4. Spray 2-3 basecoats within the intercoat clear area going further out with each coat.
5. Continue the finishing flow coats.

Does this sound right?

you might want to urethane clear out past the base and let it dry, then carefully wetsand it. Then it will be at the same point as the rest of the finish so your flowcoat will have the same texture throughout.

Ah yes, that makes perfect sense! Thanks.

Let's hope I don't blow it the second time.

Depends on the size of your burn throughs. Normally I'll just blend the base in and then roll right to the flow coats.

It took me two tries to get it right, but I finally got it. Let me just say metallic is MUCH harder than a solid color.

First time, I managed to blend it, but at different angles the light reflection didn't match. I showed other people and they said it was fine, but stuff like this makes me cringe. Second time around I managed to get it to my likings. Man I love Barry's intercoat, it was a life saver.

Brian how do you manage to do it without an intercoat? I find it awfully hard trying to blend it, with the clear all scuffed up. I feel like I'm shooting blind.

Just depends on size and placement of the burn through. You are correct through the Intercoat is a life saver. I use that stuff for all kinds of things. I couldn't be without it now.