Saltydog,
It's very ironic you started this post when you did, I was going to start the same topic, with the same delema, and airbrush.....how wierd! Anyway dude, It sounds like you came to the same conclusion as I did. What I did specifically was similar to your final experiment; except I had a brand new Iwata HP-C with the (.3mm nozzle/needle) I was itch'in to spray the camo with. What I finally came up with that simulated the free-hand "tight blended" demarcration lines for my 1/72nd scale A-7D was the following:
1. I thinned *brand new bottles of MM Dark Tan, Dark Green, and Medium Green enamels 1:1 with T.R.P.S. (Turpintine Replacement Paint Solvent) Available from your local home or Sherman Williams chain.
2. Strained the paint through panty hose and stirred it well
3. I dropped the air pressure to approx. 10 psi
I got "THE FINEST", softest, atomization of any of my Iwatas I'd ever seen yet. I was very impressed to say the least. I had no over spray, no spattering, no clogs, no spitting at all....it was effortless! Shocking becuse the small nozzle/needle size of the HP-C has been long thought of as not designed for or ideal to shoot our hobby paints.
A few observations: With spraying thinner paint, It took longer to build-up the color, but the extra coats didn't hide or deminish. The airbrush was easier to clean due to the high thinner to paint ratio, and the lower pressure allowed for slower, deliberate and steadier spraying of the camo. Anyone with an HP-C give it a shot!
Greg Williams
Owner/ Manager
Modern Hobbies LLC
Indianapolis, IN.
IPMS #44084