I have had similar experiences w/POR-15, if the part to be coated is rough and rusty, the stuff bonds with it like crazy, but on smooth clean metal, it can be made to peel off. It really is designed for bonding with rusty surfaces, the rougher and rusty-er, the better. Maybe someone from POR-15 can weigh in with a better explanation of why it behaves the way it does...
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