From my experience, if you miss a spot and catch it before full cure, you can patch it up by spraying that spot. But be reminded if you are not hanging the part, and say turning it over on a oven rack, the powder will get lines from laying against the rack which will just not be nice. Once the powder is fully cured, patching up areas is harder and you will usually have to respray the whole thing for it too look nice and uniform.
As far as how much area powder will cover, it depends on how thick you lay it on and how much you over spray. In my mind its better to order more than you need and be able to finish the job, rather than run out half way through. But to answer a question, a pound might not be enough, so i'd get 2 or even 3.
And as i said before turning over onto cured powder may not be too good. I honestly never have done it so i can not give you a definate answer, but even cured powder is a little soft once warm so i imagine it would blemish it. Instead i'd try to figure out a way to sit it on a rack or home made stand so only non visible areas are touched and blemished.
If i have learned anything from power coating, don't mess up, lol, stripping powder is horrible! Good luck!
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