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I am curious to know what the results would be if an incorrect tip size were used. What would happen if too small of a tip size were used? What would happen if tip size were too large?

Depends on what you are spraying.
A build primer, polyester primer, epoxy primer, base, clear, single stage??

OK I will bite

Too small

A smaller fluid tip is really gonna choke off the fluid flow so less paint is coming thru.
Less fluid less air is needed = smaller spray pattern and if air is reduced to much the air cap wont be able to atomize the paint correctly.

That being said I have used my Mini gun with a 1.0 fluid tip and my Air brush with even smaller fluid tip But Spray patterns and airflow air very different and a lot smaller.

Too large
Such as a 2.2 tip with Hi build you'll have runs every where But put a material in such as a Poly material such as Slick sand or Feather fill and a 2.2 is barely big enough.

It will go on a lot dryer, paint won't flow out,
leaving a rough surface.

JCCLARK wrote:It will go on a lot dryer, paint won't flow out,
leaving a rough surface.

With a conventional Gun yes! ( If we are trying to use say a 1.2 with Hi build primer most definitely! BUT could you get away with a 1.4 if the same material is reduced? I wouldn't do it but I am sure someone will say they have done it, again I wouldn't do it. The whole idea behind Hi build is to Hose it on to sand it off any way lol.

BUT with The epoxy I use a 1.8 is recommended but I spray it with a 1.4 all the time.
So I think the real question should be how small is too small when X? material is being used.

'68 Coronet R/T wrote:Depends on what you are spraying.
A build primer, polyester primer, epoxy primer, base, clear, single stage??

Most definitely!