Thermal metal spray galvanised shell?

[afishe]

I have come across a few companies in both the UK and NZ that are using thermal metal spray technology to effectively zinc (or 50/50 zinc aluminium) coat classic car body shells and suspension components. There is a VW restorer in the UK that is actually using it to seam seal and fill holes (although I am not sure about that).

Can also be used as spray on filler (like the old lead loading) in place of epoxy type fillers - it can be used as high build and while it is molten when it leaves the gun it hits the metal at around room temp so does not cause distortion.

I do like the idea of a galvanised CSL shell - for obvious reasons and cant really see a downside.

It is a really interesting process - well worth checking out some of the videos. As I say - there is a company here that will do it (and it isnt that expensive)

Anyone had any experience with this process?

http://www.vanshack.com/pages/flame-spray.html
http://www.autoblast.co.nz/service/arc-spray-galvanising/
http://www.vanshack.com/pages/pdf/introduction _to_anti-corrosion_metal_spray.pdf

They use it on oil rigs - 25 year life, in the ocean...

 

[Honolulu]

Interesting process, but vaporizing zinc for spraying has got to be toxic as H - E - double chopsticks. The shop area will be lousy with particles, and only without any wind or breeze would it not become airborne. Wash your hands really really well.... Although this process may not be as toxic as urethane paints, I wonder about the type of respiratory protection being used (I have a background relating to asbestos and lead paint).

Years ago I was learning to gas and arc weld and encountered galvanized metal. This was in the 1970's - even then the tech in charge warned me not to breathe any of the smoke/vapors. They did have a strange smell...

 

[autowerks]

Amazing Metallisation process, our cars can be rust free and daily driven

 

[afishe]

Amazing Metallisation process, our cars can be rust free and daily driven

hi. yes - that was my thoughts - I plan to get my CSL shell done after metalwork is finished.

The process has been around for many years for commercial/industrial applications - when you see a bit of steel that has a matt rough light grey finish - that is usually spray galvanising. It has only recently that a few companies have adapted it for delicate body shells with 50/50 zinc/aluminium wire for a better surface finish.

The coating is porous so the first coat of primer sinks right in and bonds really well.

I live by the sea so a fully galvanised (although they cant get into closed in spaces I guess) shell is going to be quite important - I wouldn't want to drive it in the rain and sea spray otherwise - not after putting so much money into it!