Not All Coating Jobs Are Created Equal
I’ve been handling orders for PPG industrial coatings for about six years now. I’ve personally made (and documented) twelve significant mistakes, totaling roughly $8,000 in wasted budget. Now I maintain our team’s checklist so others don’t repeat my errors.
If you’re looking for a one-size-fits-all answer on how to spec a coating job, you’re not gonna find it here. The right approach depends on what you’re coating, how much you’re ordering, and whether you care more about durability, appearance, or cost. I’ll walk you through three common scenarios I’ve personally messed up – maybe you’ll see yourself in one of them.
Scenario 1: Powder Coating & the Caps & Plugs Disaster
In September 2022, I submitted an order for powder coating a batch of custom brackets. I specified PPG’s standard polyester TGIC powder, but I completely forgot to include caps & plugs for powder coating in the prep instructions. The parts came back with powder inside the threaded holes – $1,200 of scrap because I assumed the shop would mask them automatically. (Spoiler: they didn’t.)
Here’s what I learned the hard way: if your parts have threaded holes, blind bores, or areas that must remain uncoated, provide the caps & plugs yourself and mark the drawing. Don’t rely on the coater’s standard practice. Small shops especially appreciate a client who brings their own masking supplies – it shows you’ve done this before. And if you’re a small shop ordering a low volume (like 50 brackets), don’t expect the coater to carry every size of cap. Bring your own. I now keep a bin of assorted silicone caps in my office. That $40 investment has saved me thousands.
Scenario 2: Dupli-Color Vinyl/Fabric Coating Paint – When You Just Need a Quick Interior Fix
Earlier this year, a client asked me to refresh the vinyl seats in their classic car. The budget was tight – they didn’t want to reupholster. I grabbed a can of Dupli-Color vinyl/fabric coating paint HVP (the HVP series is specifically for vinyl and fabric). Seemed simple, right?
Well, I ignored the prep instructions. The can says to clean the surface with a special degreaser and sand lightly. I figured a quick wipe with alcohol was enough. The result? The coating peeled off within a month. $180 wasted (the cost of the paint, labor, and the client’s disappointment). Put another way: I could’ve spent $15 on a prep kit and saved the whole job.
If you’re doing a small interior project – say, one car seat or a boat cushion – follow the manufacturer’s prep to the letter. Dupli-Color’s HVP formula adheres well when you do. And here’s the small-client-friendly part: I ordered just two cans from American PPG Coating Service (their online store) with zero minimum. No one looked down on my $40 order. Today that client is ordering $5,000 worth of powder coatings from us. Small can mean potential.
Scenario 3: Finding the Right PPG Service Center for Small Orders
When I started out, I assumed that a big company like PPG wouldn’t care about my tiny orders. I once drove an hour to pick up a gallon of touch-up paint because I didn’t think the local PPG Pittsburgh Paints East Longmeadow MA branch would serve a guy with a single gallon request. Turns out, they were happy to. The counter guy even gave me a tip about water-thinning ratios for their waterborne products.
Which brings me to a weird question: why is water referred to as a universal solvent? I asked that same guy while waiting. He explained that water dissolves more substances than any other liquid – which is exactly why it’s the base for modern low-VOC coatings. In chemistry terms, its polar nature lets it break apart ionic compounds, making it ideal for suspending pigment particles. But from a coatings perspective, that same property means you have to be careful: water-based paints can lift old solvent-based layers if the prep isn’t right. That’s a mistake I made once (in 2020) – painted water-based over old enamels without sanding. The finish wrinkled, and I had to strip and redo. $300 down the drain, and the delay cost me a weekend.
So if you’re a small business or a DIYer, don’t hesitate to walk into a PPG service center (like the one in East Longmeadow) with a small order. They won’t snub you. And ask questions – the counter staff deal with pros and hobbyists alike. They’re usually happy to share practical knowledge.
How to Tell Which Scenario You’re In
Here’s a quick self-diagnosis:
- You’re in Scenario 1 if you have metal parts that need a durable, heat-resistant coating and you’re outsourcing the powder work. Ask yourself: Did I provide caps & plugs for powder coating? If not, you’re at risk.
- You’re in Scenario 2 if you’re painting vinyl, fabric, or flexible plastic inside a vehicle or boat. Did you read the prep instructions on that Dupli-Color can? If the answer is no, go back and read them.
- You’re in Scenario 3 if you need a small quantity of paint or coating and worry that a major supplier won’t serve you. Is there a PPG Pittsburgh Paints location near you? Call first. I guarantee they’ll take your $50 order.
One last thing: this advice is accurate as of early 2025. PPG updates their product lines quarterly, and coatings technology evolves. So always check the latest Tech Data Sheet (TDS) for the specific product you’re using. And if you’re unsure about prep, ask – I learned that the expensive way.