Pretty frustrating eh, KC? Your "over-spray" is more likely bounce-back that you get from too much pressure out the tip. More like a conventional gun. You always want to use as little pressure as will atomize the paint. 60 pounds is way too much. If you have to use excessive pressure, the gun's asking for thinner paint. Then if you thin the paint too much you get other problems. Zahn cups measure viscosity of the paint if you're in question. Go to an autobody supplier for one. Could be the gun. Make sure your tip was meant for your product. You might need a larger hole. I have neither of your guns and I don't have a lot of faith in either of your sources, Sears or Harbor Freight. I'm assuming the Sears gun was meant to be used with a standard compressor and not a gun dedicated to be used with a turbine, like mine is. With mine, you'd never get enough air through a 3/8" line. I think mine's 1". What you're describing, assuming a compressor-type gun, sounds like you'll be taking it back to Sears. If you've had the correct tip off, took a look, and messed with the adjustments, there's just not a whole lot there.
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