what happens if powder is too thick?

[defed]

i just got a new PC gun, the one that is supposed to be able to do 10 coats, cold. so while i was redoing some parts that my old gun messed up, i decided to see if it would really do that many coats.

i had a wrench that had 1 coat of red. we redid 4 batches of satin black parts where i coated the wrench each time. then we had 2 batches of red, repeating the process on the wrench. so now it has 7 coats of powder on it.

it looks great. there is so much powder on it that the writing on the wrench is practically filled in. i dropped it on the floor and a chip came off the edge of the box end. so i hit it on the table (edge on edge) a few times and another big chip came out, down to the metal. i can see where the powder dented before it failed. if i hit it on a flat face, no problem, just dents it a bit. the coating is hard, can't scratch it very easily. if i pick at the edge of the chip w/ my fingernail, i can't peel it back any more.

my question is, w/ that many coats, does the coating become easier to chip since it is so thick? or possibly due to so many bake cycles on the inner coats it chips easier?

[FigureLLC]

w/ that many coats, does the coating become easier to chip since it is so thick?

you got it. the thinner, the stronger.

[ty1854]

Just don't go to the other extreme and get it to thin or you will get orange peel. Just coat the part until it is opaque then back the gun away from the part go back over the part with a dusting of powder. Then check for light spots with a LED light. If you can see the substrate through the powder with the light you need to apply more powder to that area. After you do this for awhile you will just know what the proper thickness looks like.

[defed]

thanks guys.

Doc, you know which gun i got ....i just had to see how many cold coats i could do! normally, i wouldn't have 7 coats on a part! just surprised me at how hard the finish was, yet so brittle, so i figured it was because it was so thick.