DIY Network

1962 Ford T-Bird Restoration: Powder-Coating Engine Parts From "Classic Car Restoration" episode DCR-307

Some of the engine parts have been upgraded using new high-performance components. In this segment, some of the original parts that will remain on the car get dressed up with a new look.

In this segment, Kevin Tetz of paintucation.com demonstrates the technique of powder-coating engine parts using an ordinary oven.

Materials:

Powder-coating kit and equipment
Parts-blasting cabinet (optional)
Standard kitchen-oven

Safety Equipment:

Respirator mask
Work gloves
Safety glasses or other eye protection

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Note: This is a summary of steps included in the automotive restoration procedures shown in this episode of Classic Car Restoration. These are general guidelines for restoration procedures on this particular make and model of vehicle, and for the level of restoration selected for this project. There may be variations in procedures depending on model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgrade kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select.

Safety Alert: Always wear eye protection when working with power tools or pneumatic tools.

	Figure A
	Figure B

Do-It-Yourself Powder Coating

Traditional methods of applying new finish to metal parts has typically include either brush paint or spray paint in a can. Now, with new advances in powder-coat technology, it's possible for you to apply powder-coat at home. In this segment, Kevin Tetz from Paintucation.com shows how it's done.

Powder-coat in a home kit form is incredibly versatile and very cost effective. The process uses a powder (figure A) that's applied to bare metal parts using a specialized spray gun. The coating is actually created from plastic powder granules that actually melt onto the part. An advantage of powder-coat over paint is that it's resistant to most chemicals including most automotive fluids, and even chemical solvents and thinners. Powder-coating has been used in industrial applications for years, and it's very strong and durable.

We decided to use the powder-coating process on a few of our engine accessories (figure B). Since the items will need to be baked in order to melt and set the powder-coat, the items selected need to be ones that can fit into a standard oven. Because of the baking process, plastic pieces cannot be powder-coated -- only metal parts. Parts such as metal brackets, lids, and tanks are well suited for the powder-coating process, and the new finishes will really dress up an engine

• Before applying the powder coat, the parts need to be stripped down to the bare metal surface. For our project, we were fortunate enough to have access to a blasting cabinet for stripping painted metal parts (figure C). If you don't have access to a blasting cabinet, you can strip them using chemical strippers or hand-sanding.

• The blasting cabinet makes quick work of stripping and cleaning parts. The gun is used to fire very small pieces of abrasive media at the item. The abrasive action of the media is enough to break down the dirt and paint (figure D). It's important to remove all of the paint and have an absolutely clean surface for the powder coat to adhere to. There are various types of blasting media used for this process -- from fine sand to glass beads to ground walnut shells. In our case, we use a polymer-bead media which is great for removing paint without damaging the part.

  Figure C

  Figure D

  
  

  Figure E

• Once the parts have been cleaned and stripped of paint, the parts are suspened from the metal oven rack using stainless-steel wire which is included in the powder-coat kit. It's critical to use stainless steel wire since it won't off-gas or release any chemicals which could cause staining the curing process of the powder-coating. The kit also comes with fiberglass tape (figure E) which is used to tape off sections where you don't want the powder coating -- such as bolt-threads and machine surfaces.
  

  Figure F

• The powder-coating technique is actually an elctro-plating process, which involves creating a static charge on the metal surface to be coated. The powder-coating equipment (figure F) includes transmitter equipped a trigger assembly, a ground clamp and the powder-coating gun. The electrostatic application creates a positive charge and a negative charge resulting in the sprayed powder being attracted to the part. Each individual part being coated is connected to a grounding wire, which creates the negative charge. An air compressor drives the powder out of the applicator, and the particles are then drawn to the negatively charged metal surface.

  Safety Alert: Because this process involves chemicals and fine, aerosolized particles, it's critical to wear a respirator mask during the powder-coating process.
  

• Once the ground-wire is attached to the first part to be coated, Kevin begins the process by spraying the powder onto the part (figures G and H).

  Figure G

  Figure H

  
  
• Like a magnet, the metal surface draws the fine particles and begins to be coated (figure I). Since this is dry powder, unlike paint there is no danger of runs or drips. Powder is only drawn to the areas where it's needed, creating a nice, even coat.

• Once all the parts have been completely coated with powder, the rack with the parts suspended is carefully placed into the oven (figure J). The parts are then baked at 450 degrees for 10 minutes. The parts are then left to cure for an additional 15 minutes.

  Figure I

  Figure J

  
  

  Figure K

Note: We chose a black powder-coat finish for our parts, to remain historically accurate to the original parts. Colored and even iridescent powder-coats are also available.

In the segment that follows, the Thunderbird gets an ignition-system upgrade with an electronic ignition for more reliable start-ups.

RESOURCES :

Classic Car Restoration Guide: The Complete Illustrated Step-By-Step Manual
Model: 1850108900
Author: Lindsay Porter
Order this book from Amazon.com
Haynes Publishing

Classic Car Restorer's Handbook: Restoration Tips and Techniques for Owners and Restorers of Classic and Collectible Automobiles
1557881944
Jim Richardson
(November 1994)
To order this title from Amazon, click here.
H.P. Books

Thunderbird Restoration Guide, 1958-1966 (Motorbooks International Authentic Restoration Guides)
by William Wonder
Published by Motorbooks International, June 1997
ASIN: 0760303908
To order this book from Amazon.com, click here.

Illustrated Thunderbird Buyer's Guide (Motorbooks International Illustrated Buyer's Guide)
by Paul G. McLaughlin
Publisher: Motorbooks International (July 2000)
ASIN: 0879388706
To order this book from Amazon.com, click here.

The Eastwood Company

The Eastwood Company is a supplier of automotive-restoration parts, tools and supplies.

The Easthill Group, Inc.
The Eastwood Company
Website: www.eastwoodco.com

Vintage Thunderbird Club International
www.vintagethunderbirdclub.org
The Vintage Thunderbird Club International (VTCI) is an organization dedicated to the restoration of Thunderbirds and is an excellent resource for many aspects of restorations. The organization establishes juding rules and offers technical advice and production data.

T-Bird Sanctuary
Supplier of Thunderbird parts and supplies. www.tbirdsanctuary.com

Classic Car Restoration 300 Series also thanks:

Ford Motor Company
www.ford.com

Advance Auto Parts
www.advanceautoparts.com

Krause Publications
www.krause.com

3M Corporation
www.3m.com


Bend-Pak / Ranger Inc.
www.bendpak.com


G S Distributing Company
Knoxville, TN

GUESTS :

Kevin Tetz
paintucation.com
Paintucation.com specialized in automotive body, paint and restoration services and instructional restoration videos.

Keller Wallace
Keller Wallace Street Rods
Volunteer Street Rod Association
Knoxville, TN