Q. What is the maximum amount of 2# pour foam I should mix at one time?
A half gallon of part A and a half gallon of part B for a total of 1 gallon.
Q. How should I work with 2# pour foam for larger projects?
You can layer on multiple pours. Wait at least 30 minutes between pours at 70F to ensure the previous layer does not collapse when the next layer is poured.
Q. How long would it take to cure the entire 10 gallon 2# pour foam kit?
If you are pouring into the same space/void/cavity using the same hole/opening for each pour, mixing the maximum (half gallon of each side at a time) and waiting 30 minutes between pours, it would take about 5 hours total. People usually pour foam into different holes/openings into a single space/cavity/void, which will decrease the time to about 2.5 hours.