Surface prep for 2024-T3 human powered vehicle

Hi everyone,

I am a hobbyist working on a recumbent bicycle made of riveted/bonded aluminum -- mostly 2024-T3 .025" Alclad sheet with a few 6061-T6 components. The techniques used are all standard aircraft methods -- formed sheetmetal components are match drilled and prepped; pa room temperature cure 2-part epoxy is applied; and the components are assembled using rivets. My immediate intention is to build one for my own use and see how it goes.

What do you folks recommend for a safely applicable, environmentally friendly surface treatment protocol? My goal is corrosion protection for a vehicle lifetime <= 10 years and, if possible, adhesion promotion as a bonus.

The experimental aircraft community spans a wide range, from those who don't worry about priming at all (usually for 6061-T6) to those who conscientiously chromate conversion coat and zinc chromate prime each and every part. However, my situation is different from the experimental aircraft for a variety of reasons -- mainly related to the short intended lifetime of the entire vehicle and its low capital cost.

Thank you very much for any and all help. Peace,

If you do not like the idea of chromate, consider type II sulfuric anodizing. If that is not an option, consider a phosphate coating. a good powder coat or a great wet paint should follow any of the above.