To factor in the amount of varnish used for costing purposes, keep a crane scale near the bake oven & dip tank. Use the crane scale to pick up the stator to be dipped and record dry and wet weight before placing the stator into the oven to cure.
To develop a costing formula, do not use a weight per HP. Instead, multiply HP times poles to obtain a relative number which can be ratioed when someone forgets to weigh a stator.
Example: A 350 hp, 12-pole stator used 80 pounds of resin, but a 400 hp, 4-pole only used 31 pounds.
350 x 12 = 4200
400 x 4 = 1600
4200 / 1600 = 2.625
2.625 x 34 = 81
It won’t always be this close, but it’s certainly better than x pounds per HP.