Powder Coating 101

What is Powder Coating?

Why Is Powder Coating Better?

• More Durable - Powder coating gives consumers, businesses, and industry one of the most economical, longest-lasting, and most color-durable quality finishes available. Powder coated surfaces are more resistant to chipping, scratching, fading, and wearing than other finishes. Color selection is virtually unlimited with high and low gloss, metallic, and clear finishes available. Thanks to the UV resistance of many of the powders, colors stay bright and vibrant longer. Texture selections range from smooth surfaces to a wrinkled or matte finish, and rough textures designed for hiding surface imperfections.
• Protects the Environment - Powder coating is also highly protective of our environment. While liquid finishes contain solvents which have pollutants known as volatile organic compounds (VOCs), powder coating contains no solvents and releases negligible amounts, if any, of VOCs into the atmosphere. Thus, there is no longer a need for finishers to buy costly pollution control equipment. In addition, most powder coating overspray that does not adhere to the part can be retrieved and reused. Although this is not always practical for many low-volume users, this can virtually eliminate the waste commonly found in liquid finishing processes.
• Saves Money - Elimination of VOCs and reduction of wastes saves money and helps companies comply more easily and economically with the regulations of the U.S. Environmental Protection Agency. In fact, one of the major elements in expanding the market for powder coating has been the implementation over the past 30 years of stringent air pollution control legislation.

Where Is Powder Coating Used?

• Appliances - The appliance industry benefits from powder coating on front and side panels of ranges and refrigerators, washer tops and lids, dryer drums, air-conditioner cabinets, water heaters, dishwasher racks, and cavities of microwave ovens. Powder coating has also replaced porcelain enamel on many washer and dryer parts.
• Architecture/Building - The architectural and building market powder coats aluminum extrusions used on frames for windows and doors and modular furniture. Many highway and building projects use powder coating on light poles, guard rails, signs, posts, and fencing.
• Automotive - Henry Ford once said, "You can have a Model-T in any color you want. So long as it's black." For an industry once focused primarily on manufacturers' needs, powder coating is transforming the automotive industry with faster production times and lower operating costs, plus irresistible value propositions for consumers. For years, conventional liquid coatings were the standard for the automotive industry. But these coatings can emit dangerous VOCs at their application stage. Powder coatings eliminate most environmental concerns and the need for costly waste disposal systems. Because powder does not run or drip, the result is a uniform, superior-quality finish.

Conversion from liquid to powder clearcoats for auto body exteriors is moving rapidly. Powder topcoats resist acid rain, the sun's ultraviolet rays and road and weather damage, helping cars retain their "showroom look" much longer and improving their resale value. BMW and Volvo are using it on their new model cars, and GM, Ford, and Chrysler have formed a consortium to test this technique on their production lines.

Powder coating has made substantial inroads as a primer for car, van and pickup truck bodies in the United States. Auto body primers in colors will be next.

There is huge market potential for high-heat resistant powder coatings on aftermarket mufflers, which resist corrosion, protect against nicks and prolong the life of the muffler. Some companies are already applying heat-resistant powder to aftermarket mufflers, and the new-car market is thought to be two or three years away. Powder coating is also applied to wheels, grilles, bumpers, door handles, roof racks and exterior and interior trim. "Under the hood" uses include oil and fuel filters, brake pads, engine block casings, suspension components and radiators. Pickup truck and SUV owners can purchase powder coated side steps, bed rails, luggage racks and toolboxes as dealership add-ons or in aftermarket stores and catalogs.

Performance car owners can find powder coated special suspension units, carburetor parts and valve covers, plus flashy rear-view mirror mounts and other exterior adornments.

Everyday Products - There are also innumerable everyday uses for powder coated products such as lighting fixtures, antennas, and electrical components. Farmers have powder coated tractors and farm equipment. Fitness buffs powder coat golf clubs and golf carts, ski poles and bindings, snowmobiles, bicycles, and exercise equipment. Shop owners have powder coated display racks, shelves, store fixtures, and vending machines. Office workers use metal furniture, computer cabinets, mechanical pencils and pens, thumbtacks, and other desk accessories that are powder coated. Parents have powder coated baby strollers, cribs, metal toys, and wagons. And home owners have lawn mowers, snowblowers, barbecue grills, patio furniture, garden tools, electronic components, bathroom scales, tool boxes, and fire extinguishers which benefit from a powder coated finish. The powder coating boom has just begun - expect more exciting uses in the near future.

Powder Coating Guns and Kits
HotCoat Powders
Powder Coating Books and Videos

PAINTING YOUR OWN CAR

If you are restoring a vehicle, a milestone in the restoration process is when you have the vehicle painted. At this stage, although still far from finished, the project really starts to take shape. Depending on your skill level and ambition, you may wish to tackle the paint job yourself.

If you have never painted before, the idea of painting your vehicle may seem like a fun project, or it may seem overwhelming. Although there are proper techniques to spraying, nothing is out of the scope of a hobbyist that is willing to practice and learn. To get you started, Eastwood offers books, videos, paint guns, paints, technical advice, and all of the supplies you need to paint your vehicle. When you see your vehicle freshly painted, the sense of accomplishment is the greatest reward.

A large part of a successful paint job is directly related to the preparation efforts. Painting a vehicle is a tedious process that involves a lot of preparation. If you do not properly prepare the vehicle for paint, you will see defects in the finish and you may experience adhesion issues. In terms of preparation, we are referring to: rust repair, damage repair, bodywork, block sanding, using the correct products, keeping the surface clean, proper sanding, etc. If you are willing to put in the time and work, the end results can make it worth all your effort.

Everyone has different reasons for wanting to paint their car - maybe you like to be able to say you did "all" of the work yourself, maybe you can not afford to have it painted, maybe you want to learn something new, maybe you want to be certain of the work that is going into the vehicle before and during paint....and the list goes on. Regardless of your reasons, there are certain things that need to be considered for a successful paint job.

GETTING STARTED

To get started, you need to develop a game plan. The key to a successful paint job is planning your steps, taking your time, and properly prepping the surface. If you are in a hurry, DO NOT attempt to paint your car. If you cut corners prepping the vehicle for paint, this will be seen in the final finish or shortly down the road. To properly paint a vehicle, there is a lot more involved than spraying paint onto the vehicle. When developing your game plan, here are several things to consider:

? Do you have a place to prep and paint the vehicle?

? Do you have (or are you willing to purchase) the needed tools to paint a vehicle?

? Will the vehicle be stripped to bare metal or are you going to paint over the existing finish?

? Are you painting the complete vehicle (door jambs, trunk area, underhood, etc) or only the outside?

? What type of paint do you plan on using? - Acrylic Enamel, Urethane, Acrylic Lacquer, Base coat/Clear coat, Water-based, etc.

? What brand of paint system are you going to use?

If you are considering the idea of painting your vehicle, first think of where you are going to prep and spray it. Do you have a dry place to store the vehicle while you are prepping it? Ideally, you will want to be spraying in a clean, dirt-free, temperature controlled environment. Are you going to rent a spray booth, paint in your garage, or paint in your driveway? Is it legal to spray a vehicle where you plan to paint? All of these factors must be considered before you think about picking up a paint gun. Tip - If it is illegal for you to paint your vehicle in the area you live, you can still strip it down and prep it for the body shop. This is a good way to save money.

EQUIPMENT OVERVIEW

Speaking of paint guns, you will need the proper equipment to paint a vehicle. At a bare minimum, you will need a paint gun, an air compressor that can meet the demands of your paint gun, and a moisture separator. The moisture separator will ensure that you have a dry air supply. Moisture in your air supply is an easy way to ruin a paint job. Another option is a turbine paint system, such as the Accuspray. These systems do not require an air compressor, and the turbine systems ensure that you have a dry air supply.

In addition to the spraying equipment, there is safety equipment that you will need. You will need a painter's suit, an approved respirator, goggles, and disposable nitrile gloves are a good idea. The chemicals in today's paints are dangerous and can be absorbed through your skin and eyes. When working with these chemicals, you must follow all precautions and make sure you use all of the required safety equipment.

PAINT GUNS

There are two general paint gun designs: gravity feed and siphon feed. Gravity feed guns have the cup mounted on top of the gun and use gravity (and air pressure) to feed the paint into the gun. Siphon feed guns have the cup mounted under the gun and use a pick-up tube to deliver the paint to the gun.

In addition to gravity feed and siphon feed designs, paint guns are commonly known as either HVLP (high volume low pressure) or conventional. HVLP paint guns pass a high volume of paint through the gun's nozzle at a lower pressure (as low as 10 psi at the air cap). Conventional paint guns require high pressure (60 psi or more) to spray the paint. HVLP paint guns generally have higher transfer efficiencies, meaning that they put more material on the item you are spraying. This results in less overspray and less wasted material. Some areas require that you paint with an HVLP paint gun or a compliant non-HVLP paint gun.

We recommend that you use a gravity-feed HVLP paint gun. With a siphon-feed gun, there is always a little material left in the bottom of the cup that doesn't get sprayed. The gravity-feed design allows you to spray the full cup of material. Also, you should consider using cup liners or the 3M PPS system. Both of these items will allow you to spray at different angles, even upside-down. Eastwood offers a variety of paint guns from DeVilbiss, Binks, Sata, Sharpe, and more.

Depending on the type of paint you plan to spray, you may need additional tips & nozzle caps for the gun. Some paint guns come with tips and nozzle caps to spray heavy primers, while others are better suited for spraying lighter-bodied paints and clears. For lacquers, enamels, urethanes, base coats, and clear coats you will want a spray gun with a 1.3 - 1.5mm fluid tip. For spraying water-based automotive paints, such as Auto Air, you will want a spray gun with a 1.0mm fluid tip. For heavy paints and primers, a spray gun with a 1.8 - 2.2mm fluid tip is ideal.

TAKE IT APART OR NOT?

When deciding to paint your vehicle, how far do you plan on taking the vehicle apart? Are you going to remove the hood, trunk, doors, glass, etc, or are you going to tape it up and paint while it is together? Taking everything off allows you to make sure there is no hidden damage and it allows you to get paint into all of the nooks and crannies. However, you will have to deal with gapping the panels, reinstalling glass, replacing seals, etc.

If you decide to paint the vehicle while it is still together, remove as many of the small items as you can - antennae, door handles, lights, locks, wipers, etc. Nothing looks worse than a nice paint job that has overspray all over items that shouldn't have been painted. If you are leaving items on the car that are not going to be painted, be sure to use a quality automotive masking tape and masking paper....newspaper does not cut it. Newspaper is porous and can allow paint to get through to the surface below. Tip - To get paint under seals that are installed, an old trick is to take some nylon clothesline or coated wire and to put it under the seal and then mask off the seal. This will lift the seal enough to allow paint to spray between the seal and the body of the vehicle.

STRIPPING THE VEHICLE

Do you plan on stripping the vehicle to bare metal or painting over the existing finish? Stripping the vehicle to bare metal allows you to see what is hiding under the paint - rust, body filler, shoddy repairs, and other damage. You'd be surprised what has been found under existing layers of paint. Stripping the vehicle to bare metal also allows you to know exactly what products are being used. If you paint over an existing finish (this is perfectly acceptable