Protective coat on external sheet metal parts

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Major System Category:
Task: Deploy additional coating to protect exposed sheet metal (optional)
Parts: All sheet metal parts
Prerequisite Tasks: Remove parts from chassis
Additional Costs: Powder coating ($250 - $500), DIY ($60 -$120)
Time Requirement: Off and on over several days
Date Started: July 2, 2012
Date Completed:

There are couple of ways to go with this. If price is no object, then take everything off the chassis and have it professionally powder coated. You will get a tough, durable coating. If this is a $50,000 project, then do nothing. If you land somewhere in the middle, you can separate the parts into those that will be exposed to the elements and those that comprise the tunnel, and just powder coat the external pieces. There is one other alternative.

The first thing you're going to do once you get the panels back from the powder coat shop is start drilling holes into that beautiful baked on finish. You will develop scratches in the powder coat, because a drill will slip or something will bang against it. If you're like me, this will drive you CRAZY. I have drawn a fair amount of attention from the neighborhood since the GTM arrived. Plus I'm the only guy on the block with a four post lift. My neighbor Ron suggested I might want something other than powder coating that could be repaired. So I did some research.

This is the spray can version. It takes a while to shake up, because it is really thick. A can does not go that far either. It is about 25% the cost of powder coating.

Plasti Dip is a rubberized coating that can be sprayed or brushed on to a surface. The label warns you to do this in a well ventilated area - they aren't kidding. This stuff has a real paint smell to it. NAPA
carries this stuff, although they may have to get it from the warehouse. I found that if the warehouse had it on hand, I could pick it up by 2:00 PM. (We have a great Napa store in Corcoran, Minnesota!) It comes in black, camo, smoke and clear.

This is the LH inner wheel well prior to being riveted to the chassis. It has been coated with Plasti Dip. This is a dull black finish. Since most of this area is hidden from view by the awesome tires and super duper paint job, who really cares if it is dull or shiny.

Here are the benefits from this approach:

1. Cost is approximately 25% of powder coating.
2. Panels never leave the build area. (This is a big for me. There are many parts and some are easy to misplace.)
3. Rubberized surface cuts down on noise. 
4. Repairable.

Here are the draw backs:

1. It is not as pretty as a shiny powder coated surface.
2. It is not as durable.