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How To Remove Powder Coating From Aluminum

A very common way to paint aluminum is with powder coating; it is sprayed onto the metal when it is very hot, where the powder melts and creates a secure bond that will last for many years. If you aren’t happy with a particular powder coating job or you would like to change the color, it can be quite simple to return your aluminium to its original state.

Step 1: Set up a work area outside or in a garage (or large room that can be ventilated by opening doors and windows). Hang the aluminum object up via hooks so that you can easily access it all the way round.

Step 2: For areas of the powder coat that you do not wish to remove, cover them with some paper bags. Make sure that you tape the bags down, along all the ledges, with masking tape to fully protect the area.

Step 3: Spray the sections of the aluminum that you want to remove the powder coat from with an industrial strength gasket remover. Leave the object to sit for 15 to 20 minutes; you should notice the coating start to bubble and peel.

Step 4: Use a dry rag to wipe over the aluminum and remove the peeling powder coat. If you notice remaining spots of the coating, give them a spray with the gasket remover and leave to sit again.

You should be able to pick up some gasket remover at an automotive store in your area; just make sure that you wear heavy, long-sleeved clothing, gloves, safety goggles and a respiratory mask when working with it.

You should also throw away the rags used to clean down the aluminum, as the remover is actually quite poisonous.

Dry ice is a great substance for performing “science experiments” with proper adult supervision.

In this experiment I placed a small amount of water inside a latex glove and added about 4 spoonfuls of dry ice, then quickly tied the end of the glove in a knot and hung it off the porch from an ornamental candelabra.

The most difficult part is handling the dry-ice safely. Ideally you and a helper should wear gloves. One holds the glove open while the other spoons dry ice into it.

Make sure if you try this at home that you and all spectators watch the expanding glove at a safe distance. When the glove bursts small fragments of dry ice may fly free and there is a risk of some hitting someone in the eye! You have been warned!

The glove expanded very rapidly as soon as it was tied closed. The size you see at the start of the video was reached in a few seconds (before the camera started rolling). However things slow down from there and the experiment was left unattended with the camera rollling before it finally burst well over 30 minutes later. This may be an anticlimax for young scientists. You can speed things up by squirting the glove with a little water to make the dry ice sublime faster or burst the glove with a sharp object (but be careful!). Note that if you put insufficient ice in the glove or your knot leaks a little then some gas may escape and the glove may never burst.

I created this video with the YouTube Video Editor (http://www.youtube.com/editor)