[Livinincolor]

Sounds like you may have several problems. The one problem I do know about is you cannot spray powder coat over a part that is already coated. I have tried and like you said, the new powder bounces off! The already cured and hardened powder does not seem to conduct the charge needed to attract the new powder. All previous coatings need to be removed unless it is real chrome plate which will conduct a charge. I have tried to put candies over chrome (powder) bases and it does not seem to work for us. As to the electric unit needing repair or not, I could only speculate. If the area you spray in has an electric charge already (maybe it is very dry there), that would hamper good results. If your spray area is already somewhat charged with static electricity, that won't help. I have often wondered if the guns last that long...actually, it' not the gun so much as the transformer. I would like to hear from others on a way to test the electrical output of the unit to make sure it is still good.