Published by Paul Foster, Owner – All Valley Powder Coating (AVPCoating)
Phoenix & Glendale, AZ | AVPCoating.com
Why You Shouldn’t Apply Powder Coating Thick to Fill Holes or Gaps
Powder Coating Isn’t Filler—Here’s Why That Matters
A common question we get at AVPCoating is: “Can powder coating be applied extra thick to fill holes, dents, or imperfections?” The short answer? No.
Powder coating is a finishing solution, not a patch or filler. It’s meant to adhere to clean, solid metal surfaces to provide durability, corrosion resistance, and an attractive finish. When used incorrectly—such as trying to “bury” flaws under extra powder—you can end up with more problems than solutions.
Why You Can’t Use Powder Coating as Filler
1. Powder Only Bonds to Metal
Powder coating requires a solid, conductive metal surface to form a strong bond. It won’t stick to air, holes, or gaps. So if you try to apply thick powder over cracks, porous welds, or dents, it will likely flake off during curing or shortly after installation.
2. Over-application Causes Defects
When powder is applied too heavily, it can cause:
- Orange peel texture
- Poor flow and uneven appearance
- Runs or sags during curing
- Improper curing, leading to a weak finish
Applying powder too thick compromises both appearance and durability.
3. It Won’t Fix Poor Welds or Damaged Metal
Powder coating is only as good as the prep underneath. If your part has:
- Gaps in welds
- Deep dents
- Unfilled seams
- Cracked or porous metal
…those issues must be resolved before coating. Powder coating won’t hide or fix structural problems. In fact, it often highlights them, so reach out the powder quoting professionals for specific questions or to request a free quote.
What You Should Do Instead
Proper Prep is Everything
At AVPCoating, we always emphasize the importance of prep. That includes:
- Metal finishing to repair imperfections
- Grinding, sanding, or welding to create a uniform surface
- Filling small flaws with metal-based fillers or welds (never Bondo)
- Thorough blasting to clean and roughen the surface
Only after that do we apply a precision powder coat to seal and protect your part.
Common Myths About Powder Thickness
Myth 1: "Thicker is Stronger"
Reality: Over-applying powder weakens the finish and may cause it to chip, peel, or flake.
Myth 2: "It Will Smooth Out Dents"
Reality: It won’t. Powder coating follows the existing contours of the metal. If there’s a dent, it’ll still be visible.
Myth 3: "You Can Hide Weld Gaps"
Reality: Gaps or pinholes in welds often bubble during curing due to trapped gases. Proper metalwork is the only real fix.
Trust AVPCoating for Precision Prep & Coating
Whether you’re restoring vintage car parts, coating a new architectural frame, or refinishing gates and fencing, AVPCoating delivers premium powder finishes by focusing on what matters:
- Surface integrity
- Proper pretreatment
- Controlled application
- Flawless curing
We serve clients Valley-wide from our Phoenix location and specialize in large, complex, and high-volume projects. If you want it done right, don’t take shortcuts—start with the pros.
Call Now
Have a Question About a Flawed Part?
Let us inspect it and provide the right solution before coating. We’ll let you know what repairs (if any) are needed for a flawless finish.
Get a quote today or talk with Paul Foster directly.
📍 23449 N. 35th Dr, Glendale, AZ 85310
🕘 Hours: Mon–Fri | 7 AM – 3 PM
📧 Email: info@avpcoating.com
📞 Call/Text: 623.201.9931
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