#7
I was spraying some EnduroVar and the first coat went fine. After the second coat I noticed the horns on the air cap were covered with finish. Is this from being too close when spraying or was it something else?
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#8
Hard to say, could be too close, not enough exhaust air, too high pressure at the gun. I always clean the air cap and end of the needle after every coat. I drop the air cap in ammonia water or lacquer thinner between coats.

John
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#9
Are you using a turbine unit? If so, it's called back spray. When shooting only about psi, you there isn't enough air pressure to push away the fog. Backing up the gun should help.
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#10
Thanks for the help. It is a gravity feed conversion gun. I backed off the inlet pressure just a little, took the filter off my exhaust fan and tried to keep the gun a little higher. In the end there was a little residue on the air cap but not as bad as before.
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#11
I've never been able to completely eliminate build up on the air cap.  I doubt it's really possible.  Your changes sound good.  As long as you can get through a spray session without buildup affecting the spray pattern then I'd call it good. 

John
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