2nd weekend of powder coating – problems with powder black

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    I did the intake manifold for my 944S in EW Powder Black this weekend. This was an interesting endeavor because there were several parts of the manifold that I could not coat with a “wrinkle” powder…. specifically the sealing surfaces at the head and throttle body, the fuel injector holes, and the hose barbs. I coated those items with gloss black first then went back with the wrinkle.

    Everything went perfect with the gloss coat. I put it in the oven until the powder flowed out then pulled it out. I let it cool then masked it off for the wrinkle coat. Wrinkle powder went on well and it went in the oven till it flowed out. When I checked on it after 5 minutes only part of it had flowed out but the silcone plugs that were in the fuel injector holes had ALL fallen out.. they were (obviously) not in very tight. They each fell onto the intake runner and left their imprint in the flowing powder. I pulled the pugs out and closed the door so the rest of it could flow out.

    A few minutes later it had all flowed out and I pulled it out so I could remove the masking tape from the gloss black area. I sprayed a little more powder on the areas the plugs had screwed up and it went on well. I stated pulling the rest of the plugs out and all of a sudden one the coat hangers holding the manifold let go and the manifold went crashing to the floor (the 2nd coat hanger let go right after the first failed). There were some damaged spots with aluminum showing through but nothing too bad. I sprayed a little more powder on these spots but it really did not want to stick (the manifold had cooled off a lot by this time). Then it went back in the over to cure. 20 minutes later there were a lot of spots that still looked glossy. I put it back in for 5 minutes and it was better but still had glossy areas. I put in in for another 5 minutes but didn’t notice any change.

    Here is what it looks like:




    Overall I’m happy with it and glad the mishaps didn’t cause more problems than they did. I’m disappointed by the plethora of glossy areas in the wrinkle areas. Was this caused by putting the powder on too thick and it ran? Is there anything I can do at this point to make it better?

    Thanks in advance for any advice.

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