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About to do this for the first time to some Terminators. Given the extreme thinness of airbrush layers, is it good policy to apply multiple lights coats, or keep the spray up and give it one thorough coat. Also, I'm using Vallejo satin - any suggestions on PSI? I'm assuming no thinner as well.

Any other general advice? I'm loving how the paint came out on these guys using the airbrush and I'd hate to flub it with a boneheaded application of varnish.

One coat should be fine, but two coats won't hurt anything. You do not need to thin it (I believe is says not to thin on the bottle). If you choose to do multiple coats, make sure you allow a couple hours of drying time between coats. I usually varnish around 20-25 psi, but I've done it at lower and higher pressures and notices no real difference.

I will admit I have only ever used an airbrush to body paint and do makeup but...

How do you guys keep the nib from clogging when using a varnish? 50/50 with 98% alcohol?

I use the spectra tex matte varnish with my Sotar 20/20, it does gum up a little bit on the tip after a few seconds to a minute, but that is no different than any other tip dry as far as I'm concerned, I clear the issue, and get back to it.

Well... with a hand held can you flip it over hold it for a second to clear it. Again my airbrush stuff is normally used with body paints and makeups so I would probably never run paint paint thought it anyway Just wondering

As Scooty mentioned, thin coat.

A thick coat may not dry properly and can fog.

As for PSI and thinning, thats all about your airbrush and product.

If its Vallejo Model Air Satin Varnish, it should spray through just about anything at about 15 psi, but fine tune to whatever gets the best results from your set up.

Don't be afraid to practice on something thats not important!

If its Game of Model Color Satin, you have some thinning to do, and for varnishes I actually suggest sticking with manufacturer airbrush mediums. Intermixing stuff can do odd things and make slight shades of tint that can throw off your whites or other delicate colors(its rare- but it can happen. Chemistry can be random!)

If you get fogging in your varnish, apply a coat of gloss varnish and try again.

Also, test it on some spure, or a test mini or a piece of spure with your color scheme to make sure it gives the result you want BEFORE putting it on your minis.

I run my varnish at about 20-30 psi, as I am not doing any kind of fine detail, and I mix it with a few drops of alcohol (91%).

I have used liquitex varnishes, testors model masters acryl and miniatire through my brush. My preferred is the model masters acryl, but thats purely subjective.

as far as keeping the tip from drying, I don't do huge amounts at once...or I might mix in tiny bit of dryingretarder or flow aid.

best of luck, and hope it goes well!