Zinc Metallisation for Car Chassis & Panels
Zinc metallisation, also called zinc spraying or thermal metal spraying, gives steel car parts some of the best long-term corrosion protection available. At Maldon Shot Blasting & Powder Coating, we use it on chassis, body shells, panels, subframes and other steelwork that needs to last, especially on restoration projects.
What Is Zinc Metallisation?
It’s a thermal spray process. Zinc wire is melted and sprayed onto freshly blast-cleaned steel, where the molten particles flatten, cool and lock onto the roughened surface to build up a solid layer of zinc.
Zinc protects steel in two ways. It forms a barrier between the steel and moisture, and it’s also sacrificial: if the coating is scratched or chipped, the surrounding zinc corrodes instead of the steel. That stops rust creeping under the finish, as it does with paint alone.
Our Zinc Metallisation Process
- Blast cleaning: removes rust, old paint, filler and underseal, leaving a clean, roughened surface for the zinc to grip. See our car body blasting service.
- Zinc spraying: pure zinc is applied soon after blasting, before the bare steel can start to oxidise.
- Sealing: an epoxy primer seals the zinc and provides a base for the top coat.
- Finishing: the part is then ready for paint or powder coating in your chosen finish.
Why Metallise a Car Chassis or Body Shell?
- Long-term rust protection for chassis, subframes, floor pans, sills and panels.
- Sacrificial protection that keeps working even if the finish is chipped.
- An ideal base for paint or powder coating.
- Much less risk of heat distortion than hot-dip galvanising, because thin panels aren’t dipped in molten zinc.
- Suitable for large items, such as complete body shells, that won’t fit a galvanising tank.
For exhaust parts and other components that run very hot, we also offer an aluminium plasma coating. See the plasma section of our ceramic coating page.
Example: Nissan Skyline
This Nissan Skyline body was blast cleaned, given a pure zinc metallisation coat, and sealed with an epoxy primer before its final finish.
Find out more about metallisation at Maldon Shotblasting & Powder Coating.
Zinc Metallisation FAQs
Is zinc metallisation better than galvanising for car parts?
Both use zinc to protect steel. Hot-dip galvanising involves dipping parts in molten zinc, which can distort thin car panels and is limited by the size of the tank. Zinc metallisation is sprayed on, so there’s far less risk of distortion and it can be used on complete body shells, chassis and panels.
Can you paint or powder coat over zinc metallisation?
Yes. Once sprayed, the zinc is sealed with an epoxy primer, which gives a sound base for paint or powder coating in your chosen colour and finish.
Can you metallise a complete car body shell?
Yes. We regularly blast clean and zinc metallise complete body shells for restoration projects, as well as chassis, subframes and individual panels.
Does zinc metallisation add much weight?
Very little. The coating is only a fraction of a millimetre thick, so even on a complete body shell the added weight is typically just a few kilograms. Call 01621 841100 to discuss your project.