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Powder coating will crack,this stuff is like glass,once flexed it will develope small spider cracks but as far as a Corvette frame goes I dont think this would happen here.Ive seen a cross member that did this but you cant beat powder coating for being convenient.If you want the frame to look as good as possible go over the entire surface and smoth out any surface rust,powder coating wont hide a ratty surface.
We powder coat frames all the time. Cracks will happen if the piece you are powder coating is not prepped correctly. It's more than sandblasting and than shooting powder over it. We also own the 4th largest powder coating company in FL. We can powder coat 6 frames at a time. See if your powder coater washes the parts before he soots them and bakes them. If he doesn't, find somewhere else or you will have flaws in it later on.
I was just about to say that, for the coating to properly adhere you have to properly prep it and have the frame go through a phosphate bath, this is especially critical if you have your frame flame zinc splayed otherwise the coating will not adhere properly. There are also other prepping methods but the phosphate rinse is the most common. If you use the proper powders, prepping technique and curing temps/time it will be as durable as it gets, no chipping and no cracking.
Once the frame is powder coated how do you attach all the ground wires without breaking the surface and letting moisture get under the coating?
You will have to plan ahead and screw a bolt and washer into the holes before the powder coating.
What worries me about powdercoating a frame (from a New England perspective) is that rust can work its was underneath the powdercoat and eat away at the metal happily for years before you see a problem. Case in point: I just had to replace the powdercoated front springs on my wife's Volvo XC (2001 with 78 K miles) because one of the springs had rusted under the powdercoating and broke, Fortunately it happened when she pulled into the driveway and not hitting a pothole on the highway. When I examined the other spring I found there was corrosion in the same place under the powdercoat.
If you powdercoat the outside of a frame you have to make sure you coat the inside also to insure that moisture doesn't eat the metal from the inside out.
I love powdercoat, photos of chassis being coated on website, end of first folder. It hold up if prepped properly and does have some flex without cracking. You can touch up over it with matching paint if needed. After some minor mods I've had to touch up were coating was removed. Be sure to plug all bolt holes etc prior to coating. Acetone will remove coating were needed.
You just can't beat its durability