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Mark, I'd like to think that the Powder Coater has something to plug the holes. If you come up with your own design just make sure it can withstand the 450 degree temps.
They guy that powder coated mine had these cork shaped rubber or urethane thingies.... :crazy: ...they plugged the holes with that.....he should have somthing.
Yes, Eastwood does sell a complete PowderKote kit as well as the "high temp" plugs. They also sell a "high temp" fiberglass masking tape.
Mean Green 2000: your PowderKote guy should have the plugs and/or tape to keep the powder out of the proper areas. If not, then he should be able to easily get them. You could make your own; just like was mentioned above, make sure they can withstand 450 degrees. Another option is to look at the "low temp" PowderKote product. This stuff works/looks the same as the regular stuff but cures at around 250 degrees. For calipers, this should work fine; many have used regular auto paint on them with no trouble ;) And, the lower temp may make it easier to find stuff to "plug the holes".
BTW, the Eastwood plugs are made from high temp silicone and are generally red in color.
I did it even easier and bought some Hi-Temp engine paint and masked off the inner fender well and body with blankets and newspaper and then spray painted them. I then hand painted the letters with factory touch up paint. I have raced on the track and driven in stop and go traffic and my calipers have not chipped, cracked, or faded.
I believe that PowderKote does have a dark green color; won't be exact, but should get kind of close. Or, talk to your PowderKote guy; you can have "custom" colors created (I've heard they can duplicate almost any color). The only down side is cost; you have to purchase a whole "brick" of the custom color.
I would think that PowderKote's darkest green with the "micro prism" additive, you would get real close to DBGM :)