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Powder Coating Risers and Elbows

Mxzx

Contributing Member
I've got a guy that will powder coat my 8 new risers and elbows inside and out for $200. He says he can get complete coverage in the jackets and it has been tested to 1000 hours salt durability. Puts it on 2-3 mils thick.

What do you guys think? I am looking for extending the replacement interval due to rust and clogging, don't really care about external appearance.

Thanks!!
 
I was once in the equipment end of this business, and while I don't know any specifics on this potential application, here are a few things to think about. The powder paints are usually an epoxy, an acrylic, or a blend. They are organics and will burn off at exhaust gas temperatures but in the water passages (where corrosion starts) the temperatures would be fine for long life. The powders are charged and stick to the iron though electrostatic attraction. The iron part is then heated in an oven to melt the powder which, as a liquid, flows out to smoothly cover the surface. The liquid then cures (cross links) to form a permanent, non-melting solid coat. Sounds good but it is very difficult to get a good coating of the powder in interior passages due to the Faraday cage effect. I doubt that complete coverage in the curved passageway of a riser is possible in a typical commercial powder coating setup. A gun that uses frictional charging (instead of a high voltage power supply) helps a lot but can only take you so far. Also after the powder melts (and loses it's charge) but before it cures, it may tend to flow off of high peaks on the surface (such as is the case with sand castings), leading to pinholes. Finally, while the paint is durable, the bond between the paint and the metal is dependent upon the cleanliness of the surface before painting. This would be hard to insure in an internal passage way. Most powder paint failures are seen months or even years after application and can usually be traced back to cleanliness issues.

In short, while I think powder coating would likely help extend the life (perhaps considerably), I would not trust it unless the process for doing so was carefully developed, tested and controlled. And since elbows must be changed before they start to leak, and you really cannot inspect them, it would be a guestimate as to how much longer you would be willing to go before change out.
 
I then wonder if maybe I just have him do the risers? For $100 might be worth a shot since those are the ones that are a bear to get off the manifold? The elbows can be removed and cleaned out periodically I guess?
 
We do powder coating at work. I'm not sure how to get the thin/long passages coated. Pretty much have to pour the powder in there?? Then it melts and not sure how to inspect such a process.
 
it won't cost nothing but money to try it out.....as noted above, I'd be skeptical about the coverage being complete...a borescope should let you inspect most of the passageways...the water discharge ports in the elbow would be the toughest area to deal with .... just make sure the finished coating does not work like an insulator or you could have bigger problems.
 
Ayuh,.... As long as powder coatin' has been around, If it actually worked as discussed in this thread, I gotta believe it would be SoP by now,....

It Ain't, so I have serious doubts that it'll hold, 'n not peel off, cloggin' the water passages,.....
 
Maybe I'll just forget the whole thing then. I did get 25+ years out of the old ones, so maybe these will last half as long!!
 
OK, we all agree that powder coating is probably not a good idea. Thinking about how car bodies are coated with a dip process I thought maybe liquid was the way to go. I did a quick look at alternatives and found that guys that restore old outboards find a lot of water passage rust issues. They repair them and use coatings to stop further deterioration. I saw one recommendation for filling with zinc chromate paint diluted 50% but most seem to agree that a coating called "POR 15 Rust Preventative" is the way to go, with the cleaning being a "Metal Prep" that is also sold by the same firm. This is supposed to give good heat transfer and long life in salt. Anyone willing to try coating the water passages of a new elbow and tell us in 6 years what they found? It is an intriguing idea. I certainly would like have elbows with double or more of life.
 
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No wonder these things rust out, what a crappy coating of paint on brand new Crusader parts!

Oh well, tried to attach a picture but no luck.

I think I will try the POR 15 experiment.
 
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