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Sprayed water base stain, let dry 24 hours,applied post catalyzed sanding sealer and let dry 24 hours. Sanded and applied post cat conversion varnish. After several days of curing the topcoat released from the sealer. Any ideas?
Need more info. For instance, is the Sanding Sealer and Top Coat from the same manufacturer, and did you add the correct catalyst (# of ounces) to each product?
Here's some questions for you;
Which waterbased stain did you use?
The sealer and topcoat are from the same brand. They are designed to work with each other specifically. Sanded with 320 and topcoated within a couple of hours. I know the topcoat released from the sealer because the stain was still sealed good. I could not get through the stain with water, thinner ,etc. It had to be sanded to cut through it. When I say releasing I mean you could get a corner of the topcoat with a razor blade and slice it off easily.
What brand and product?
Based on what you describe you definitely lacked intercoat adhesion. Your topcoat may have set up too quickly to allow itself to wet into the contours of your 320 sandscratch pattern. It may have bridged the ridges of the scratch instead of allowing itself to reside in their contours.
Adding retarder might help along with going with a wider scratch such as 280 grit.
Also to note, if your scuff material was at all dull then instead of creating a nice tooth you were instead burnishing your surface, a recipe for a failed finish, one which will suffer from lack of intercoat adhesion.
Good luck and hope this helps.