Thread: Hideous paint failure

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Incorrect prep is your problem. Washing with any detergent will leave residue on the surface that HAS to come off. Rinsing with water will not do the job. Your first mistake was sanding the box without cleaning it first. Any sanding you did has driven oils and junk down into the surface.
This is a process I use when I paint anything that may have stuff on it I don't know about...
1) Wash the item with TSP (Trisodium Phosphate) mixed in hot water. TSP is a cheap degreaser used for washing houses and equipment prior to painting. It can be had at a hardware store for a few bucks a box. Use a power washer if you can and water as hot as you can get it. (The power washer may work for you to strip this paint job also because it has no real "hold" on the substrate. A high pressure wash may strip all of it off. Worth a try?)
2) Wash the surface down with Prep-Sol or Pre-Kleano BEFORE doing any sanding and BEFORE spraying any paint... This is a must... Sanding on a dirty/greasy/oily surface will only make it harder to clean and yo will be surprised how much easier the surface will sand when it is clean...
It sounds like you have a big job ahead of you to make the jop right... good luck.
Mark