RandyMarsh303
04-10-2012, 02:39 AM
So per request here is a DIY on powder coating metal parts
First Here is a little information on the actual powder coating process. Powder Coating is a electromagnetic finishing process that uses pigmented powder that is dispersed by a specialized application gun. The powder is positively charged and by grounding the parts the powder clings to the bare metal. The parts are then baked in an oven at about 400-600 *F depending on the powder type. The small beads of powder melt and combine creating a finish similar to paint. Many times these coatings do not even require any kind of clear coat. This coating is also extremely durable but is not usually suitable for high heat applications for the obvious reason of it becoming liquid at 4-6 hundred *F.
Now very large industrial ovens and powder guns and racking systems are in place at your local shop and can provide an excellent coating for you but it will cost you. For the same cost of coating several parts you could be up and going with your own equipment. I will be using a much larger system then your average DIY system but the process is the same. I will include links to powder coating suppliers of all the things you need to get going.
Here is a list of things you will need to start powder coating on your own
Sand Blaster
Blasting Cabinet/Shelter (your options are flexible)
Blasting Media
Powder coat gun
Powder
Part Hooks
Oven: This needs to be devoted to powder coating and can not be used for food. DO NOT USE THE OVEN IN YOUR KITCHEN. If you are able to hook up an oven in your garage just look on Craigslist. Sometimes you can find them for free in the free section.
Latex gloves
Leather Gloves/Welding Gloves/Oven Mitt...you get the idea
A place to hang you curing parts
Much like painting the surface needs to be completely clean and free of dirt, oils, paint, plating, rust, etc.
We start by stripping the parts down to bare metal. Remove any kind of hardware or grommets that are on your parts. Also any gasgets that can be peeled away do that at this time. Note: Gloves must be worn at all time when handling the parts from this point on to avoid oils from getting on the metal.
https://sl-i.net/FORUM/images/imported/2012/04/DSC03142-1.jpg
https://sl-i.net/FORUM/images/imported/2012/04/DSC03143-1.jpg
These parts are then sand blasted to remove any contaminants
https://sl-i.net/FORUM/images/imported/2012/04/DSC03145-1.jpg
The surface of your metal will determine the final finish. NO powder will hide imperfections just like paint so plan on taking the time to do it right and really get everything clean. Also if you are coating something that is not brand new don't expect it to come out lookin' like tits magee.
This was made from a piece of steel that came from the scrap yard so you can see how the metal is a little aged and rusted
https://sl-i.net/FORUM/images/imported/2012/04/DSC03158-1.jpg
https://sl-i.net/FORUM/images/imported/2012/04/DSC03159-1.jpg
This is a brand new aluminum part straight from the store
https://sl-i.net/FORUM/images/imported/2012/04/DSC03160-1.jpg
https://sl-i.net/FORUM/images/imported/2012/04/DSC03161-1.jpg
This is the Powder room. Obviously you will not have this but if done in an open garage you will be fine, just expect for there to be some over spray of the powder. This room is designed to pull all the dust towards the filter wall and at the top of the room is a grounded panel that parts will hang from. When doing this with your home system you will most likely be hanging them from the oven rack or they will be resting on the oven rack in some way. Pay attention to where you are putting hooks because powder can be easily wiped away by the hook.
https://sl-i.net/FORUM/images/imported/2012/04/DSC03148-1.jpg
This is the Gun System
https://sl-i.net/FORUM/images/imported/2012/04/DSC03146-1.jpg
https://sl-i.net/FORUM/images/imported/2012/04/DSC03144-1.jpg
This is the powder that is used
https://sl-i.net/FORUM/images/imported/2012/04/DSC03170-1.jpg
These are the blasted and ready parts
https://sl-i.net/FORUM/images/imported/2012/04/DSC03148-1.jpg
The gun is then loaded with powder and it is as simple as spraying the powder onto the part checking the complete coverage is achieved. Settings will differ from gun to gun so refer to your specific gun owners manual for details concerning gun settings.
These are parts with fresh powder. Care must be taken not to touch the parts and/or to keep it from moving around on the rack/hook.
https://sl-i.net/FORUM/images/imported/2012/04/DSC03162-1.jpg
https://sl-i.net/FORUM/images/imported/2012/04/DSC03164-1.jpg
https://sl-i.net/FORUM/images/imported/2012/04/DSC03163-1.jpg
As you get used to your gun you will get better at judging the thickness and evenness of the powder. Just keep an eye out for these sort of things...
Parts are then loaded into the preheated oven. On this oven, a constant thermostat provides accurate temp readings. The parts should bake for about 15-20 depending on manufacturer recommendations. This time should not be started until the internal temp is back up to 400 *F after the parts have been put in. Getting an oven thermometer is a good idea because it will provide a better reading for you.
https://sl-i.net/FORUM/images/imported/2012/04/DSC03167-1.jpg
After 20 min take parts out of the oven and allow them to cool
https://sl-i.net/FORUM/images/imported/2012/04/DSC03171-1.jpg
Remove from the hook and TA DA! You have just saved your self a boat load of money and now just think of all the things that you can powder coat. You are only limited by the size of your oven :smt023 :smt023
Now luckily for you lovely people while I was taking all these photos for this write up I screwed these parts up. I was in a big hurry and did not take the time to make sure there was even coverage. The neon green was hard to tell what was coated fully. Parts can be done multiple times but keep in mind it is best to keep it with one coat. You can see below where some parts did not have enough powder on them and needed to be re coated.
https://sl-i.net/FORUM/images/imported/2012/04/DSC03152-1.jpg
https://sl-i.net/FORUM/images/imported/2012/04/DSC03153-1.jpg
https://sl-i.net/FORUM/images/imported/2012/04/DSC03154-1.jpg
https://sl-i.net/FORUM/images/imported/2012/04/DSC03155-1.jpg
https://sl-i.net/FORUM/images/imported/2012/04/DSC03151-1.jpg
This is from the hook rubbing the powder while dry and or wet
https://sl-i.net/FORUM/images/imported/2012/04/DSC03156-1.jpg
Now on to the where do I get that portion...
-Sand Blasters
Harbor Freight offers a variety of options along with Blasting cabinets as well
NorthernTool.com
-Blasting Cabinet
If you have the resources and the space you can fabricate one from metal or wood but the best for the DIY'er is to get a cheap cheap single or double man tent from ebay. This will give you space for you parts and still allow you to gather back up your blasting media.
HarborFreight.com
NorthernTool.com
Eastwood.com
-Powder guns
Eastwood.com Offers a number of starter packages to choose from. Dont bother getting the packages with all the color unless you really think you are going to use them. Purchasing a package that includes a few colors 1-3 is fine to get you started and familiarized with the system but then move to just buying it by the pound.
-Powder
PowderByThePound.com is hands down the best place to get ANY and I do mean ANY color your heart desires
-Oven
Craigslist is your best bet
I think I have covered most of it but im sure im forgetting something obvious so please if there are questions bring em' on...
First Here is a little information on the actual powder coating process. Powder Coating is a electromagnetic finishing process that uses pigmented powder that is dispersed by a specialized application gun. The powder is positively charged and by grounding the parts the powder clings to the bare metal. The parts are then baked in an oven at about 400-600 *F depending on the powder type. The small beads of powder melt and combine creating a finish similar to paint. Many times these coatings do not even require any kind of clear coat. This coating is also extremely durable but is not usually suitable for high heat applications for the obvious reason of it becoming liquid at 4-6 hundred *F.
Now very large industrial ovens and powder guns and racking systems are in place at your local shop and can provide an excellent coating for you but it will cost you. For the same cost of coating several parts you could be up and going with your own equipment. I will be using a much larger system then your average DIY system but the process is the same. I will include links to powder coating suppliers of all the things you need to get going.
Here is a list of things you will need to start powder coating on your own
Sand Blaster
Blasting Cabinet/Shelter (your options are flexible)
Blasting Media
Powder coat gun
Powder
Part Hooks
Oven: This needs to be devoted to powder coating and can not be used for food. DO NOT USE THE OVEN IN YOUR KITCHEN. If you are able to hook up an oven in your garage just look on Craigslist. Sometimes you can find them for free in the free section.
Latex gloves
Leather Gloves/Welding Gloves/Oven Mitt...you get the idea
A place to hang you curing parts
Much like painting the surface needs to be completely clean and free of dirt, oils, paint, plating, rust, etc.
We start by stripping the parts down to bare metal. Remove any kind of hardware or grommets that are on your parts. Also any gasgets that can be peeled away do that at this time. Note: Gloves must be worn at all time when handling the parts from this point on to avoid oils from getting on the metal.
https://sl-i.net/FORUM/images/imported/2012/04/DSC03142-1.jpg
https://sl-i.net/FORUM/images/imported/2012/04/DSC03143-1.jpg
These parts are then sand blasted to remove any contaminants
https://sl-i.net/FORUM/images/imported/2012/04/DSC03145-1.jpg
The surface of your metal will determine the final finish. NO powder will hide imperfections just like paint so plan on taking the time to do it right and really get everything clean. Also if you are coating something that is not brand new don't expect it to come out lookin' like tits magee.
This was made from a piece of steel that came from the scrap yard so you can see how the metal is a little aged and rusted
https://sl-i.net/FORUM/images/imported/2012/04/DSC03158-1.jpg
https://sl-i.net/FORUM/images/imported/2012/04/DSC03159-1.jpg
This is a brand new aluminum part straight from the store
https://sl-i.net/FORUM/images/imported/2012/04/DSC03160-1.jpg
https://sl-i.net/FORUM/images/imported/2012/04/DSC03161-1.jpg
This is the Powder room. Obviously you will not have this but if done in an open garage you will be fine, just expect for there to be some over spray of the powder. This room is designed to pull all the dust towards the filter wall and at the top of the room is a grounded panel that parts will hang from. When doing this with your home system you will most likely be hanging them from the oven rack or they will be resting on the oven rack in some way. Pay attention to where you are putting hooks because powder can be easily wiped away by the hook.
https://sl-i.net/FORUM/images/imported/2012/04/DSC03148-1.jpg
This is the Gun System
https://sl-i.net/FORUM/images/imported/2012/04/DSC03146-1.jpg
https://sl-i.net/FORUM/images/imported/2012/04/DSC03144-1.jpg
This is the powder that is used
https://sl-i.net/FORUM/images/imported/2012/04/DSC03170-1.jpg
These are the blasted and ready parts
https://sl-i.net/FORUM/images/imported/2012/04/DSC03148-1.jpg
The gun is then loaded with powder and it is as simple as spraying the powder onto the part checking the complete coverage is achieved. Settings will differ from gun to gun so refer to your specific gun owners manual for details concerning gun settings.
These are parts with fresh powder. Care must be taken not to touch the parts and/or to keep it from moving around on the rack/hook.
https://sl-i.net/FORUM/images/imported/2012/04/DSC03162-1.jpg
https://sl-i.net/FORUM/images/imported/2012/04/DSC03164-1.jpg
https://sl-i.net/FORUM/images/imported/2012/04/DSC03163-1.jpg
As you get used to your gun you will get better at judging the thickness and evenness of the powder. Just keep an eye out for these sort of things...
Parts are then loaded into the preheated oven. On this oven, a constant thermostat provides accurate temp readings. The parts should bake for about 15-20 depending on manufacturer recommendations. This time should not be started until the internal temp is back up to 400 *F after the parts have been put in. Getting an oven thermometer is a good idea because it will provide a better reading for you.
https://sl-i.net/FORUM/images/imported/2012/04/DSC03167-1.jpg
After 20 min take parts out of the oven and allow them to cool
https://sl-i.net/FORUM/images/imported/2012/04/DSC03171-1.jpg
Remove from the hook and TA DA! You have just saved your self a boat load of money and now just think of all the things that you can powder coat. You are only limited by the size of your oven :smt023 :smt023
Now luckily for you lovely people while I was taking all these photos for this write up I screwed these parts up. I was in a big hurry and did not take the time to make sure there was even coverage. The neon green was hard to tell what was coated fully. Parts can be done multiple times but keep in mind it is best to keep it with one coat. You can see below where some parts did not have enough powder on them and needed to be re coated.
https://sl-i.net/FORUM/images/imported/2012/04/DSC03152-1.jpg
https://sl-i.net/FORUM/images/imported/2012/04/DSC03153-1.jpg
https://sl-i.net/FORUM/images/imported/2012/04/DSC03154-1.jpg
https://sl-i.net/FORUM/images/imported/2012/04/DSC03155-1.jpg
https://sl-i.net/FORUM/images/imported/2012/04/DSC03151-1.jpg
This is from the hook rubbing the powder while dry and or wet
https://sl-i.net/FORUM/images/imported/2012/04/DSC03156-1.jpg
Now on to the where do I get that portion...
-Sand Blasters
Harbor Freight offers a variety of options along with Blasting cabinets as well
NorthernTool.com
-Blasting Cabinet
If you have the resources and the space you can fabricate one from metal or wood but the best for the DIY'er is to get a cheap cheap single or double man tent from ebay. This will give you space for you parts and still allow you to gather back up your blasting media.
HarborFreight.com
NorthernTool.com
Eastwood.com
-Powder guns
Eastwood.com Offers a number of starter packages to choose from. Dont bother getting the packages with all the color unless you really think you are going to use them. Purchasing a package that includes a few colors 1-3 is fine to get you started and familiarized with the system but then move to just buying it by the pound.
-Powder
PowderByThePound.com is hands down the best place to get ANY and I do mean ANY color your heart desires
-Oven
Craigslist is your best bet
I think I have covered most of it but im sure im forgetting something obvious so please if there are questions bring em' on...