Powder Coating

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            Almost every week, Someone writes me about my experience with my latest adventure, POWDER COATING!!!  Those of you in the vehicle restoration world might appreciate a page like this.  For those of you with no idea what I am talking about, Powder coating is the 21st century method to painting and protecting virtually any metal.  My interest all started when I called a local powder coating shop for a quote on PC'ing an oil pan.  300 bucks??  NO WAY...  So off to the net I go and see what kind of advancements have been made in the realm of home powder coating.  I had heard awhile back that it was on it's way to being feasible for the do-it-yourself kinda guy. 
 
Powder coating is a unique way of refinishing parts.  If the part is able to withstand temperatures of about 400F for about 20 mins, then you might be able to use this WONDERFUL method of painting.  Try not to think of it as painting.  I personally hate to paint! Houses, cars, car parts ect.  I can't stand the fumes, overspray, cost and I am the messiest painter you have ever seen!  The "Powder" is actually more like a dust.  They come in different chemical make ups depending on your particular application.  The powder is applied to your part by "static" (more or less) ;-)  The part is grounded and the gun has the positive charge.  Compressed air is mixed with the powder and lightly sprayed onto your part.  Once the entire part is coated, the powdered part is very delicate.  The slightest touch will brush off the applied powder and you will need to reapply it.  Into the preheated oven the part goes for about 15-20 mins.  That's IT!!!  It has taken me longer to write this than to PC a small part.
 
Advantages: 
  1. Easy application
  2. Easy Cleanup
  3. No overspray
  4. Very cost effective
  5. Coating is virtually chip, scratch and rust resistant!
  6. Powders come in any imaginable color, texture, special effect, High Temp applications  and glow in the dark!
Disadvantages:    
  • Part must be VERY clean
  • Powder Coating is VERY difficult to remove!!! (read that part again!)
  • Sandblasting has little to no effect on PC'd parts
  • Part must be able to withstand ~400F for 20 mins  
  • Equipment (OVEN needed)
Now that you know a little bit about powder coating, Lets take a look at the process.

Part cleaning...  After grease, rust and dirt have been cleaned off, I send all my parts thru this cabinet I built.  I know, It's not very pretty, but it is extremely functional.  Glass beads is my medium of choice.  Stay away from silica sand.  Silicosis is a very real threat and just not worth the cheap cost.  I built this sandblasting box in an evening, It is 4x4x3 and has plenty of space to bead blast practically anything I'll come across.  I am using a cheap siphon type sandblaster and a bucket filled with the glass bead.  When the bucket is empty, I simply sweep up the piles in the box and use it again.  You'll know when it's time to change out the glass beads, progress will slow down and everything gets VERY dusty.  The larger the compressor you use, the easier your life will be.  I am using a 60gallon 7hp compressor.  Money WELL spent!
 
 
You thought this blasting cabinet was ugly!  Take a look at the next picture!!! YIKES.  If you attempt to PC at home, It is CRUCIAL that you do not use an oven that will ever be used again for cooking food.  I met someone on the net that was powder coating very small parts and he was able to use a toaster oven.  You will need to be able to heat whatever oven you choose to about 400 degrees and have plenty of space inside to place your part in there by hanging and NOT touching anything.  This can get sort of tricky with large parts, but gets easier with practice.  Parts get suspended from the rack on top with metal wire.  This allows the part to be grounded via an alligator clamp to the PC machine.  The only purpose of this box on top of the oven is simply to help capture powder that didn't adhere to the part.  I then use a clean paint brush and sweep it up to be put thru the gun again. Waste not, Want not!
 
 
 
The GUN.  Unlike painting, the quality of the gun doesn't matter.  The only real difference between a cheap gun and ones costing thousands is the strength of the electricity.  I have obtained FANTASTIC results with a 59dollar gun!  This setup came from Harbor Freight tools. Other places such as Eastwood and Caswell sell very similar units.  The Chinese are masters at bringing affordability to you and me!
 

 Here are a few examples of some colors commonly available.  These color chips are for your viewing pleasure.  Please be sure to shop at both these excellent companies for quality powders.    Eastwood Automotive and Caswell Plating.  As you can see, The sky is the limit!

 
Now that you have decided what color you want, The gun gets loaded a couple inches worth of powder in the cup.  Air pressure is set to about 10~15psi and your ready.  With the part suspended from the oven rack and grounded, the part is sprayed at about 8-10inches until it is covered with a fine layer of powder.  It will have a dull almost fuzzy appearance.  If your part has close tolerances or threaded, it is imperative that you cover those parts up or else you will be getting out the taps and chasing threads.  Trust me, It wont be pretty.  Many people use silicon plugs and covers or special heat tape that can resist the long hot temps of the oven.  Another option that  works great,  Aluminum foil!
 
 
 
Now the part is ready for baking.  The oven is set to 400F per the instructions set by the powder manufacturer.  As soon as the part
begins to "gloss over" set your timer and have a seat.  I have found when doing a very large part, the oven gets smokey, so crack the
door a half inch to allow it to escape.  People say this might cause problems with the finished project.  So I don't take any chances.
 
 
Now that the heat cycle is over, shut the oven off and prop the door open slightly to allow the part to slowly cool down.
 
   Here is the clutch slave cylinder finished.
 
 
In Conclusion:
I have been VERY impressed with doing this at home and the money I would have spent for one time to the professional,  I have completely set myself up here at home.  I do not particularly have any desire to do this for a living or profit.  So IF you come to my house with 4 boxes of all your little parts and pieces wanting to powder coat them, I'll probably say get lost!  Now if you have something like a certain special part, or special need, example valve cover,  I might be able to do something for you.  If you set up an outfit like this at your home and burn your place to the ground, or cause a public disturbance when ALL your friends line up down your street to have their stuff PC'ed, I WILL NOT BE HELD RESPONSIBLE!  Never leave your oven unattended, and operate it in a well ventilated area (Leave the garage door open and get a cheap fan) Thanks for learning about powder coating, feel free to email me if you have any questions.       Jason
 
Special thanks to:
Bill McKenna at McKenna's Garage
Caswell Plating (Powder Coating Forum)
Eastwood Automotive Supplies
Harbor Freight Tools
Caswell's Photo Album of PC... WORTH A LOOK!!!
 
Check out Eastwood below, they have everything you'll need!!!    ---Jason---
 
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