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topic 0633

Reuseable masks for powder coating


Hello, I'm looking for advice on how to solve a problem on a report I'm doing: 3 bike parts, made of Wrought 6061 T6 ALUMINUM ALLOY it is currently EPOXY POWDER coated.

PROBLEM: pre/post masking process is very labor intensive:
Cardboard is put in 2/3 holes before coating to prevent the epoxy from altering diameter hole specs.

Instead of cardboard used in these .5" 1.75" holes, looking
for another material to be used during masking process, something REUSABLE would be GREAT.

I've heard a rubber stopper could be used, ? able to withstand the 400 degree heat temperature.

epoxy powder coat cannot enter 3 main holes, looking for the most cost effective/efficient process

Any SUGGESTIONS/Recommendations would be greatly appreciated!

David Stafford
Student / Request for info

You might want to talk to suppliers of masking materials about reusable plugs. The banner ad at the top of this page will lead you. They are designed for the purpose of masking the paint from the holes and you can get silicone plugs which are designed to be reused many times and which may be able to take this 400 deg. temperature.

Ted Mooney, Teds signature
Ted Mooney, P.E.
Pine Beach, New Jersey


Silicone plugs and caps are available in many diameters. These will withstand the temperature of powder curing many times, and cost roughly $1 in a bike-tube size.

Andy Brush
finishing equipment - Strongsville, Ohio

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