Any opinions regarding bare aluminum vs powder coating vs painting the baffles?
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Powder coating baffles
- Thread starter Larry KMYA
- Start date
Bare aluminum. Doesn't take more time. Doesn't add weight. Doesn't add cost. Doesn't ever need to be repainted.
I’ve generally left them bare aluminum in the past, but the custom work on the F1 project created quite a few scratches and buffed areas, so I decided to paint. I used a Rustoleum product new to me - Epoxy Appliance Paint. A single-part “epoxy” - imagine that. I did some test pieces, let them cure a few days (it DOES take a few days), then hacked at them with scotchbrite, dental picks, etc - held up extremely well, so I’m happy! We’ll see how it holds up long term, but hey….they’re just baffles……
I've had all three; bare, painted, and now powder coated. My next door neighbor has a powder coating shop at his house and he's powder coated on all my parts including the baffles. The baffles look awesome with a nice glossy texture that will be easy to wipe down. Previously painted ones required a really good scuffing to keep the paint from peeling off. Bare aluminum.....blah
For you guys that are powder coating, are you powder coating all the parts first, assembling a few and then powder coating or powder coating after assembly?
The reason I ask is that it seems like the powder coating could flake or chip when riveted. On the other hand, riveting after powder coating puts the softer powder coat between the two pieces of aluminum. I painted mine, but believe powder coating would be a better solution if it can be done without the possible issues above.
When I painted mine, I used Stewart Systems primer under the paint....big mistake. The primer bled through when the cylinders got hot and turned the baffles a pastel green color. The paint itself held up fine, but it looks like 2 pounds of crap in a 1 pound bag. I have a couple of buddies that used wash primer under the same paint on their baffles and they look great after 150 hours.
The reason I ask is that it seems like the powder coating could flake or chip when riveted. On the other hand, riveting after powder coating puts the softer powder coat between the two pieces of aluminum. I painted mine, but believe powder coating would be a better solution if it can be done without the possible issues above.
When I painted mine, I used Stewart Systems primer under the paint....big mistake. The primer bled through when the cylinders got hot and turned the baffles a pastel green color. The paint itself held up fine, but it looks like 2 pounds of crap in a 1 pound bag. I have a couple of buddies that used wash primer under the same paint on their baffles and they look great after 150 hours.
I tried not to overthink it. High Temp Rustloleum from Ace Aircraft Hardware Store. I eye balled the powder coating system at Harbor Freight but decided on the simple aerosol solution. If I had already had the capability I would have PC. But then again this is probably why my build has taken so long 
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They do look nice.
Back in the day, we would kill for every spare ounce of weight. Nothing was added if it didn’t have a direct and evident purpose.
Today, the plus 1100# RV seems to be the norm, not the exception.
I know this isn’t much weight, it’s a philosophy of the build. I saw one recent post where the builder stated of his plus #1200 RV “ I don’t know how it got so heavy”. I do. I saw all the posts about adding this, changing that, painting this, etc….etc….
So sure, you’re only adding a tiny bit of weight and some effort in the build. We all need to make our own choices. I just don’t see a benefit other than aesthetic, and that’s ok. It’s important to feel proud of what you see when you take the cowling off.
That said. I might paint the baffles on my RV15.
Back in the day, we would kill for every spare ounce of weight. Nothing was added if it didn’t have a direct and evident purpose.
Today, the plus 1100# RV seems to be the norm, not the exception.
I know this isn’t much weight, it’s a philosophy of the build. I saw one recent post where the builder stated of his plus #1200 RV “ I don’t know how it got so heavy”. I do. I saw all the posts about adding this, changing that, painting this, etc….etc….
So sure, you’re only adding a tiny bit of weight and some effort in the build. We all need to make our own choices. I just don’t see a benefit other than aesthetic, and that’s ok. It’s important to feel proud of what you see when you take the cowling off.
That said. I might paint the baffles on my RV15.
I powder-coated the baffles on my Cessna 180 back 30 years ago. In areas exposed to ram air, dirt has gotten permanently embedded into the paint. In at east one area, the paint is peeling. For my RV-3B project, I'm leaving them bare.
Dave
Dave
I left mine nekkid. They work well and the only time they're seen is with the top cowl off. Even then with an SJ Cowl and plenum they don't get very dirty. And to be honest, even though the pc and neatly painted baffles look pretty cool, I like the looks of clean aluminum.
danny
danny
