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Anyone ever zinc plated their frame or talked to someone who did?
Pro's to doing this vs. some other method (rust inhibiting paint or whatever)?
Con's to doing this?
Can it be painted over?
It sounds intriguing to me vs. powder coating or using something like por-15 because the zinc coating would completely cover the frame inside and out, which powder coating wouldn't do. Por-15 (or any other paint like product) could be sprayed inside the frame, but how do you know you got it coated adequately?
I'm also not a fan of powder coating because of the potential (however unlikely, not interested in debating this here) for chipping or scratching and the fact that I'd have to re-tap all bolt holes. I envision that the zinc would be a thin enough coat that I wouldn't have to do that, maintaining a completely rust proof barrier.
I'm not a frame expert, but I can address one of your concerns about powder coating threaded holes. Put old bolts in all the threaded holes. Then simply crack them loose and remove them after power coating. I've had a few items powder coated and found it to be very durable and hard to scrape off of areas where you don't want it. The same goes for Jet-Hot!