MDF sunken joints

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Given a choice I would use a polyester two part primer coat over an epoxy for the simple reason that epoxy actually absorbs water. Whatever you use just take your time.

You got that the wrong way round. Epoxy is waterproof, that's why they use it to repair failed polyester lamination on boats.

P38 is ok, but you can get plastic padding ultima from halfords for less than a tenner which is better. Goes on nicer and less likely to pinhole. Sands nicer too.

Unfortunately if you got hairline gaps its a risk for the joint to show through. Good luck with the build.
 
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Richie,
Epoxies are usually considered hygroscopic, they absorb water even if it is at a low rate. I would think the epoxy being used on a boat repair has more to do with adhesion to the surface than its water proofing properties. Epoxies are usually more forgiving in impact than a polyester so that may also be another reason it is being used.
 
regarding the hairline gaps, is there anything extra I can do to help, maybe if I leave for longer after filling before sanding to allow for shrinkage?

Not really. The problem is the panels rather than being held tight against each other have something in between them. Luckily cascamite is pretty rigid, but this is the kind of thing that is important when trying to achieve total elimination of joint lines in the painted finish, so it's a risk.
 
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