Magnesium, Aluminium and ZAMAK conversion coating service.
Conversion coating is a chemical treatment process applied to magnesium or aluminium alloys surface to enhance their corrosion resistance and adhesion properties. During immersion, a chemical reaction occurs between the chemicals dissolved in the bath and the magnesium/aluminium surface, resulting in the formation of a thin, protective coating on the alloy’s surface. This layer acts as a barrier, shielding the underlying alloy from corrosion caused by exposure to moisture and environmental elements.
Many VW and Porsche enthusiasts cut corners and choose to paint their engine or gearbox cases. However, they should be aware that their engine case plays a vital role in the cooling process. A thick layer of paint acts as a heat barrier, leading to engine and gearbox overheating. Conversion coating is far superior over paint as it maintains great Thermal conductivity of magnesium or aluminium alloys. Another benefit of choosing coating over painting is its electrical conductivity, eliminating the need to strip paint to connect a ground cable.
We dialed the process of conversion coating not only to enhance the corrosion resistance but also to match the original shiny gold look of your VW or Porsche Aircooled engine.
How to distinguish between magnesium alloy and aluminum alloy?:
– Visual Observation: Magnesium alloys often have a darker gray color compared to aluminum alloys, which tend to have a brighter silver appearance. If you notice a dark gray surface with white salt-like growths, it is likely magnesium.
– Weight Comparison: Magnesium is significantly lighter than aluminum. If you have similar-sized pieces of each metal, the one that feels lighter is likely the magnesium alloy.
– Chemical Test (Caution Advised): You can perform a simple chemical test to distinguish between the two. Clean a small portion of the surface using scotch brite or sand paper, then put a drop of vinegar on it. If it reacts and produces small bubbles or starts boiling, it is likely magnesium. However, please exercise caution as this test involves corrosive vinegar and may cause damage to the surface.
You can also be sure that your engine case or gearbox is made of a magnesium alloy if your aircooled Volkswagen is from the WW2 era, such as KdF Beetle Type 60,Beetle Type 82E, Kubelwagen Type 82, Schwimmwagen Type 166. Magnesium cases were also used in type 519 gearboxes of Porsche 356 Pre-A, A, B, C cars.
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We will begin processing orders and start coating parts as soon as we reach a total of 10 orders(one gearbox case or engine case per order), regardless of whether they come from one or multiple persons. It could take days or month so we encourage clients to send us more than one part, as this helps expedite the process of reaching the minimum order requirement. By doing so, you not only contribute to the overall progress but also receive the benefits of our coating service sooner.
Additionally, clients can help speed up the process by sharing this opportunity with friends and colleagues who might be interested in our coating service.
Before shipping the engine or gearbox case to us, it’s essential to disassemble the unit completely. Remove all metal parts, including studs, bolts, and nuts, to ensure that every surface of the engine case receives uniform coating coverage. Additionally, please drill out all aluminum plugs from oil galleries.
To ensure the best results for our coating service, it is essential that the parts you send us are perfectly clean. We recommend using an engine alkaline cleaner, combined with a pressure washer, to thoroughly clean the engine or gearbox case. Removing all dirt, grease, and contaminants will enable the coating to adhere effectively, providing optimal corrosion resistance and longevity.
We recommend sending us the engine case for coating first before proceeding with any machining work. Coating the engine case before machining safeguards its integrity, as the acids used in the pickling process to remove impurities can also affect magnesium or aluminum parts by removing a thin layer of material from its surface. By applying the coating before machining, we can ensure dimensional accuracy of crucial engine features.
Please Note: Skipping the recommended preparation steps may result in additional charges. If the engine case is not disassembled, thoroughly cleaned, or the aluminum plugs are not drilled out, we will need to perform these steps on behalf of the client. Likewise, if the engine is sent to us after machining, we need to cover all machined surfaces with a protective “plasti dip” compound. These additional costs will be calculated individually based on the specific requirements. To ensure a smooth and cost-effective process, we strongly advise adhering to the preparation guidelines.
We offer our conversion coating service for a wide range of aluminum alloy, magnesium alloy, and ZAMAK/MAZAK alloy parts, up to 50x50x60 centimeters in size. While our estimated prices are based on VW Beetle engine or gearbox case dimensions, we can provide individualized quotes for parts of different sizes.