Building a Powdercoat Oven

Powdercoating is an excellent coating system, superior to paint in many ways, and is now available to the hobbyist through the coating guns offered by Eastwood, Columbia Coatings, Harbor Freight, and others. The main deterent to hobby use, though, is the fact that the coated object has to be baked at temperatures as high as 450 degrees, and for time periods up to 25 minutes, depending on the type of powder used. For smaller objects, an old kitchen oven can be used, but when the size of the object increases beyond that which will fit into a kitchen oven, the equipment cost goes up at a breathtaking rate. One of my hobbies is restoring and riding old three-wheelers, four-wheelers, and motorcycles. The kitchen oven I have in my shop will barely accomodate a wheel, and a swing arm would be out of the question. I decided to build a powedercoat oven to use in coating objects up to the size of an ATV or motorcycle frame. I wanted the oven to be collapsible so that it could be stored away when not in use. There's not much hard info on the internet about building ovens, but I contacted a few people that had experimented with this sort of thing, then made a few decisions of my own, and forged ahead. The oven is assembled from a series of panels which is actually 2" rigid fiberglass board wrapped in 28ga sheetmetal. Each panel is different from the others, but all have at least one dimension of 36", which is the largest size that my brake will handle. All fastenings are steel pop rivets, except a few screws which hold the panels together to form the oven. The base is a lightweight frame built up of light gauge metal drywall studs, with burner pans filling in the open areas of the frames. Heat is provided by 4 salvaged kitchen oven burner elements, of about 3000 watts each This was the real uncertainty for me, whether the element would heat up the large volume quickly enough. As it turned out, the oven heats up to 450deg in about 10 minutes. Temperature control is provided by a scrounged kitchen oven thermostat which controls a 50 amp definite purpose contactor to turn the elements on and off. The temperature floats a bit but it seems accurate enough. The total draw of the heating elements is about 12kw. My local power rate is 8.7cents/kwhr, so the oven would cost about $1.04 per hour to operate.

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Here is a front view of the oven. Inside dimensions are 24" wide x 36" high x 72" deep. Two of the four heating elements are visible. The shiny bar across the bottom about 1/2 way into the oven is actually an intermediate support member. It might not be clear from the picture, but the elements are recessed about 1-1/2" below the front lip of the base. A pair of rails, made from small channel iron will be laid the length of the oven and a trolley will be used to carry the coated object into the interior of the oven.

. I would use 1-1/2" angle so that the wheels would protrude at the bottom more..Home The trolley is made from 2" angle iron with 4ea fixed casters.. The various rods and pipes that protrude upward are for supporting the items to be coated. Scroll down a little further. If I were to do it over.

The rails mentioned earlier are in place and visible in this picture.Home and we have a picture of an ATV frame mounted on the trolley and being loaded into the oven. .

.Home Here is a wheel being loaded on the trolley.

Installation of electrical components requires specialized knowledge of the trade and of electrical codes. Anyone considering the construction of such an oven should consult the appropriate professionals for preparation of a qualified design. a part also taken directly from the kitchen ovens. The black box on the side of the oven is the interior light. that arise from the use of information published on this website. nor does he purport to offer advice or consultation on the subject of oven construction.Home A picture of the top of the oven showing the view windows. . These windows were salvaged from two scrapped kitchen ovens. Under no circumstances shall the website owner be responsible for any loss or damages. regardless of severity. For a closer look at how this oven was constructed. click here to go to the Construction Page. DISCLAIMER This website is presented for the enjoyment of its readers only. The owner of the website is not a professional engineer or designer. The fabrication of heat producing equipment such as an oven is an inherently dangerous process.

. This type of brake is slow to use and doesn't (in my opinion) make the sharpest bends.Home Construction Page Design Page Material List Contact Links Details of Building the Powdercoat Oven Before we start the actual construction details. Apparently some previous owner had bent the original and fabricated a homemade leaf. Those of you familiar with this type of brake will notice that the clamping leaf is not stock. but I have my doubts about whether it could handle 18 gauge steel. but it is tolerable for the purpose here. Capacity is 36" wide x 18 gauge. Here is a picture of my brake. I think discussion of a few tools is in order. The main tool needed is a sheetmetal brake. obviously a low budget model (I actually paid $50 for it at a welding shop).

The first step is building the base. The studs were laid on edge and fastened with pop rivets into a frame with two bays. . not many specialty tools were needed. available from building supply houses. Click on this picture to view a larger size.Constructruction Page A few of the hand tools used for this project. These two bays will have burner pans installed in them to enclose the bottom of the oven. A shear would have saved a lot of time and made squaring the panels a lot easier. The base is constructed from 3-5/8" metal drywall studs. Not shown is a drill for drilling the pop rivets holes. Other than the brake.

. The two outer flanges lay on the base rails and are pop riveted for fastening. This picture shows a burner pan installed in one of the bays and the heating element being installed. This pan provide support for the heating elements and prevents heat from escaping from the bottom of the oven.Constructruction Page Each bay of the base has a burner pan as the floor.

This panel overlaps the panel adjacent to it and you can . The panels are made of 28 gauge galvanized sheetmetal wrapped around a core of 2" rigid fiberglass insulation. Typical procedure was to bend a single piece of metal 4 times to form it into a rectangular box.Constructruction Page The next step is the construction of the panels that make up the shell of the oven. This picture shows placement of insulation in a panel. then fill the remaining two open ends with separate fillers. This is not the same panel as in the previous picture. This picture shows the brake making the third bend. All seams are fastened by pop rivets.

com to download the Acrobat Reader for free.Constructruction Page see the overlap protruding about 1-1/2" at the bottom of the picture. Click Here to view a PDF file of this drawing. . You must have the Adobe Acrobat Reader to view this file. Visit www. The drawing in the next frame will show better how the panels are constructed. This panel actually requires three separate fillers to enclose the insulation. Here is a drawing of the oven.adobe.

images. All text. Power (110v) is routed through the ON/OFF switch and is controlled by the thermostat. This circuit activates the coil of the contactor. The two round objects on the bottom of the panel are actually 220v receptacles. Click Here to veiw a PDF file of this drawing. The heart of the electrical system is the contactor. which is an electromagnetic switch. Click here for a larger view with labels. The thermostat causes the contactor cycle open and close to requlate the termperature. and drawings are Copyright 2004 by Gary Brady . Warning: 200K file.Constructruction Page The electrical panel shown here was fabricated from the same sheetmetal as the rest of the oven. This allows the oven to be disassembled easily for storage. Two heating elements are wired together and plug into each of these receptacles. which closes the 220v circuit that feeds the heating elements. The schematic to the left shows how the oven is wired. The oven has an interior light and switch which I have omitted here for clarity.

objects to be baked. or 12kW. An increase in insulation thickness would be warranted for larger ovens. loading from the end. while total exterior surface area is 72 square feet. Using a 2" rigid fiberglass insulation board for the entire enclosure except the base. The volume of this oven is 36 cubic feet. type of material used for construction. Utility: Utility consideratons are those physical characteristics that define how the oven will be used. If you've built an similar oven. size. type of insulation. the oven heats to 450 deg in less than 10 minutes. The exterior surface area will increase at a proportionately higher rate as the volume increases causing a greater heat loss for larger ovens. Oven design considerations are grouped into the following two general categories: Performance: Performance criteria are the physical aspects of the oven as they relate to how the oven will perform. This heat input factor would be valid only for an oven of this approximate size. This actual data indicates that a heat input of 333 watts/CF of oven volume will provide an acceptable heat up time. I'd like to collect data from your experiences. since it works will with frames as well as smaller items such as wheels. and heating element output. please contact me. The trolley type racking device was also chosen. Shape. The oven shown in this website was intended to be used for ATV frames and smaller items. and portability are all utiility considerations. Each of the four elements is approximately 3000 watts for a total of 12000 watts. The performance related criteria here are volume of the oven. . was the chosen shape.Home Construction Page Design Page Material List Contact Links Design Considerations All data presented on this page has been collected from the construction and operation of the oven shown in this website. racking of items. so the horizontal configuration of a rectangular box.

that is. etc. and in fact. Professional powdercoaters would proabably want an oven that was stationery or mounted on wheels. and drawings are Copyright 2004 by Gary Brady. may be more serivceable for some items to be coated. An overhead trolley.4t. the panels are the structure and are light in weight and easy to handle.com/Design. http://powdercoatoven.html (2 of 2)11/14/2004 8:08:27 AM . that it could be disassembled and stored away on a shelf in the rafters of my shop when not in use. There is no structure per se. One of my most important considerations was that the oven be portable. The trolley requires modification from time to time to hold different items.Design Page fenders. however. This approach is not very sturdy. the base is quite flexible unless lying flat on a smooth concrete floor. images. there is no one right way to build an oven. which rides in Unistrut mounted to the underside of the top. All text. Clearly. The type of material used for construction will probably be dictated by the capabilities and needs of the builder. similar to this one. I chose the panelized approach for this oven. The fact that I own a sheetmetal brake was also a factor in the construction that I chose.

The thermostat . The steel for the trolley and rails had already been purchased. including one kitchen oven (I'm a remodeling contractor and frequently haul old appliances to the dump). A number of items were already in my scrap bin. and was left over from a prior project. The contactor was purchased from an air conditioning supply house.heating elements.and in fact. This contactor has a 50amp capacity with a 110v coil. and view windows came from these ovens. Another oven was picked up (literally) from the side of the road. is very similar to the contactor found in the condenser unit of many home A/C units. .Home Construction Page Design Page Material List Contact Links Material List The following spreadsheet is a list of items I purchased for the construction of the oven.

Material List .

90 Order .24 Sale price: $27. (Res.. Amps 240-600V) .50 L37-844 Regular price: $162.

: ● ● ● ● ● ● ASTM C 612 .0 PCF) ASTM C 795 ASTM C 1136 (facings) . and cavity walls.25. Low-Cost Installation ● ● Lightweight.cfm?fuseaction=prd. III.S.Type I. 2.Type IB (3. APPLICATION Knauf Insulation Board is a versatile product for thermal and acoustical applications such as: heating and airconditioning ducts. It is available plain. Type I (ASJ facing).0 PCF) http://www.knauffiberglass.dspProdDetail&ID=12 (1 of 7)11/14/2004 8:10:21 AM .25. 6.Type II.0 PCF) . easy to handle and fabricate. Fast. power and process equipment.25. Appearance ● FSK.Printer Friendly Page KNAUF INSULATION BOARD DESCRIPTION Knauf Insulation Board is a thermal and acoustical insulation product made from inorganic glass fibers preformed into boards bonded by a thermosetting resin. 2. SPECIFICATION COMPLIANCE In U.com/index.0. 4. 6. curtain wall assemblies.25.6. PSK facing) HH-I-558C . IV (ASJ) . metal and masonry walls. 3. boiler and stack installations. PSK) California Title 24 HH-B-100B. IV (FSK.0. 3. Noise Reduction ● Excellent acoustical properties effectively reduce noise. II. 4. easy installation lowers labor costs. FEATURES AND BENEFITS Energy Conservation ● Excellent thermal efficiency results in lower operating costs. with a factory-applied FSK facing or PSK (metalized polypropylene-scrim-kraft) facing. Class 1 (1. Type II (FSK.Type IA (1. PSK and ASJ vapor-retardant facings provide a neat finished appearance. or with a factory-applied all-service jacket (ASJ). 4. 6.0.25. wall and roof panel systems.Form A.6.

02 perms. Puncture Resistance (TAPPI Test T803) (Beach Units) ● ● FSK. PSK Facing: 25 ASJ Facing: 50 Water Vapor Transmission (ASTM E 96. and NRC 1.0 PCF) MIL-I-24244C NFPA 90A and 90B NRC Reg. Temperature Range (ASTM C 411) ● Operating temperatures from 0°F to 450°F (-18°C to 232°C). 50 Smoke Developed when tested in accordance with ASTM E 84. APPLICATION AND SPECIFICATION GUIDELINES Precautions ● ● During initial heat-up to operating temperatures above 350°F (177°C).0. Water Vapor Sorption (ASTM C 1104) ● Less than 5% by weight when exposed to air at 120°F (49°C) and 95% relative humidity for 96 hours.36. NFPA 255. a slight odor and some smoke may be given off as a portion of the bonding material used in the insulation begins to undergo a controlled decomposition. . forced ventilation should be provided in order to protect against any harmful fumes and vapors that might be generated.● ● ● . CAN 4-S102. 4. Mold Growth (ASTM C 1338) ● No growth.36 In Canada: ● ● ● CAN 4-S102 CGSB 51-GP-10M CGSB 51-GP-52M (facings) TECHNICAL DATA Surface Burning Characteristics (UL Classified) ● Does not exceed 25 Flame Spread. Meets the stress corrosion requirements of ASTM C 795. 6. MIL-I-24244C. and UL 723.25.Form A. If natural convection is not adequate in confined areas. Procedure A) ● FSK.3% linear shrinkage. steel. or copper. PSK and ASJ vapor retarders have a maximum vapor permeance of . Class 2 (3. Shrinkage (ASTM C 356) ● Less than 0. Guide 1. Corrosiveness (ASTM C 665) ● ● Will not accelerate corrosion of aluminum.

The data is subject to normal manufacturing variations. Knauf Insulation Board must be covered with appropriate jacketing. For outdoor applications. Minimum compression is to be used to assure firm fit and still maintain thermal performance. . and equipment operating at temperatures of 450°F (232°C) or less. loose-fitting clothing.0 pcf (48 kg/m3) insulation board in concealed areas. Wash work clothes separately and rinse washer. vessels. or banded. VESSELS. Apply jacketing. the tape must be firmly rubbed with a proper sealing tool to make sure the closure is secure.Storage ● Protect material from water damage or other abuse. Prescore rigid insulation board where necessary to conform to curved surfaces. Vacuum packaged material can be stored outside if care is taken not to puncture the polybag. The data is supplied as a technical service and is subject to change without notice. Wear long-sleeved. Insulation Board is not designed to be exposed to the airstream. tanks. A disposable mask designed for nuisance type dusts should be used where sensitivity to dust and airborne particles may cause irritation to the nose and throat. Insulation can be secured with adhesive. 50 Smoke Developed. or other vapor retarder. or mastic. Fasteners shall be located a maximum of 3" (76 mm) from each edge and spaced no greater than 12" (305 mm) on center. Vapor retarders should overlap a minimum of 2" (51 mm) at all seams and be sealed with appropriate pressure-sensitive tape. Tapes should be applied using a sealing tool and moving pressure. head covering. Cartons are not designed for outside storage. Use on ducts. NOTES The chemical and physical properties of Knauf Insulation Board represent typical average values determined in accordance with accepted test methods. Tapes and mastics (dry) should have a UL 723 rating of 25 Flame Spread. AND EQUIPMENT: For irregular surfaces. TANKS. Check with your Knauf regional office to assure information is current. Where vapor retarder performance is necessary. Application GENERAL: All insulation joints must be firmly butted. Use 6. DUCTS AND PLENUMS: Use 3. References to numerical flame spread ratings are not intended to reflect hazards presented by these or any other materials under actual fire conditions. gloves. ● ● ● ● ● ● ● ● ● ● ● ● Caution Fiber glass may cause temporary skin irritation. All exposed surfaces must be protected. all penetrations and facing damage shall be repaired with tapes or mastic with a minimum of 2" (51 mm) overlap. When applying pressure-sensitive tapes. mastics. Metal ducts must be sealed before application. plenums. Follow tape manufacturer's recommendations. dry surfaces. and other vapor retarders in accordance with manufacturer's instructions. Wash with soap and warm water after handling. mechanical fasteners. mastic.6 pcf (26 kg/m3) insulation board and band with minimum compression. and eye protection when handling and applying material.0 pcf (96 kg/m3) insulation board in exposed areas. use 1. Preparation ● Apply the product on clean.

035 .24 .12 1.04 1.053 .75 .00 .92 .25 .05 .03 1.42 .31 .80 .061 .65 .42 .24 .47 .14 .050 .13 1.035 .11 .96 1.0 PCF k k k k k .6 PCF (26 kg/m3) 1.30 .032 .035 .63 .6 PCF 2.26 .06 .69 .055 .040 .0 PCF (48 kg/m3) 3.65 .06 1.25 PCF (36 kg/m3) 3.90 1.89 1.96 1.00 .0 PCF (48 kg/m3) 3.27 .035 .76 .57 .44 .81 1.22 .03 .23 .24 .85 .86 .25 PCF (36 kg/m3) 2.25 PCF 6.49 .07 . 1/3 OCTAVE BANDS (ASTM C 423.22 .37 . TYPE A MOUNTING) Type 1.24 .25 PCF 6.17 .23 .08 .06 .0 PCF (48 kg/m3) Facing Thickness 125 Hz 250 Hz 500 Hz 1000 Hz 2000 Hz 4000 Hz NRC Plain Plain Plain Plain Plain Plain Plain FSK FSK Plain Plain Plain 11/2" (38 mm) 2" (51 mm) 21/2" (64 mm) 3" (76 mm) 1" (25 mm) 11/2" (38 mm) 2" (51 mm) 1" (25 mm) 2" (51 mm) 1" (25 mm) 11/2" (38 mm) 2" (51 mm) .59 .11 .62 .43 .25 PCF (36 kg/m3) 2.043 .01 1.95 .19 .17 .6 PCF (26 kg/m3) 1.THERMAL EFFICIENCY (ASTM C 177) Mean Temperature 75°F 100°F 200°F 300°F 1.033 .28 .05 .39 .6 PCF 2.97 1.23 .07 1.38 .04 .27 .0 PCF 4.03 1.29 .34 THERMAL EFFICIENCY (SI) (ASTM C 177) 1.033 .03 1.0 PCF Mean Temperature (26 kg/m3) (36 kg/m3) (48 kg/m3) (68 kg/m3) (96 kg/m3) k k k k k 24°C 38°C 93°C 149°C .042 .02 1.048 .25 PCF (36 kg/m3) 2.99 .35 .55 .82 .033 .25 PCF 3.25 PCF (36 kg/m3) 2.03 1.00 1.03 1.29 .0 PCF 4.85 1.00 1.036 .039 .05 .033 .05 .75 .09 .6 PCF (26 kg/m3) 1.06 1.04 1.049 SOUND ABSORPTION COEFFICIENTS.86 1.04 1.25 PCF 3.6 PCF (26 kg/m3) 2.98 1.93 1.23 .62 .65 .03 1.23 .88 1.33 .75 .99 1.99 1.24 .

0 PCF (96 kg/m3) 6.60 .58 .44 1.61 .27 .47 .45 .04 1.65 .01 1.53 .65 .60 .63 .4 12.5 1.60 .71 .62 .62 1.04 1.41 .63 .42 .50 FORMS AVAILABLE* Density 1.50 .0 PCF (48 kg/m3) 3.63 .06 .95 .0 PCF (48 kg/m3) 3.0 PCF (48 kg/m3) 4.65 .24 .78 .50 1.6 PCF (26 kg/m3) 1.65 .08 .02 .51 .01 1.23 .77 1.99 .81 .00 .32 .77 .50 .06 .39 .47 .77 .18 1.24 1.55 .75 .0 PCF (96 kg/m3) 6.25 PCF (68 kg/m3) 6.0 PCF (48 kg/m3) 3.16 .47 .80 .17 .32 .26 .67 .75 .65 .41 1.05 1.35 .28 .41 .0 PCF (96 kg/m3) 6.50 .90 1.75 .1 1.69 .66 .51 .25 1.15 .72 .0 PCF (96 kg/m3) 6.31 .05 .75 .71 .10 1.0 PCF (48 kg/m3) 3.73 .0 PCF (48 kg/m3) 3.21 .60 1.3 10.54 .01 1.0 PCF (48 kg/m3) 3.61 .0 PCF (96 kg/m3) Plain Plain FSK FSK FSK ASJ ASJ ASJ Plain ASJ Plain Plain Plain FSK FSK FSK ASJ ASJ 3" (76 mm) 4" (102 mm) 1" (25 mm) 11/2" (38 mm) 2" (51 mm) 1" (25 mm) 11/2" (38 mm) 2" (51 mm) 1" (25 mm) 21/2" (64 mm) 1" (25 mm) 11/2" (38 mm) 2" (51 mm) 1" (25 mm) 11/2" (38 mm) 2" (51 mm) 11/2" (38 mm) 2" (51 mm) .48 .07 .07 1.55 .05 .06 .74 .04 1.99 .0 PCF (96 kg/m3) 6.10 .22 .70 .58 .04 .07 1.84 .6 PCF (26 kg/m3) Thickness R-Value R-Value (SI) 11/2" (38 mm) 2" (51 mm) 21/2" (64 mm) 3" (76 mm) 6.80 .07 .6 PCF (26 kg/m3) 1.93 .41 1.47 .13 .60 .23 .3 8.3.75 .48 .00 1.77 1.2 .41 1.11 .6 PCF (26 kg/m3) 1.03 .93 .91 .5 1.30 1.03 1.53 .82 .25 PCF (68 kg/m3) 4.8 2.46 .69 .0 PCF (48 kg/m3) 3.40 .0 PCF (96 kg/m3) 6.0 PCF (96 kg/m3) 6.

6 PCF (26 kg/m3) 1.0 PCF (48 kg/m3) 3.25 PCF (68 kg/m3) Privacy Policy Terms of Use 31/2" (89 mm) 4" (102 mm) 1" (25 mm) 11/2" (38 mm) 2" (51 mm) 21/2" (64 mm) 3" (76 mm) 31/2" (89 mm) 4" (102 mm) 1" (25 mm) 11/2" (38 mm) 2" (51 mm) 21/2" (64 mm) 3" (76 mm) 31/2" (89 mm) 4" (102 mm) 1" (25 mm) 11/2" (38 mm) 2" (51 mm) 21/2" (64 mm) 1" (25 mm) 11/2" (38 mm) 2" (51 mm) 14.0 PCF (48 kg/m3) 3.3 6.7 8.25 PCF (68 kg/m3) 4.2 1.3 2.5 1.6 PCF (26 kg/m3) 2.4 4.9 .6 2.9 2.1.0 PCF (48 kg/m3) 3.9 13.2 17.0 PCF (48 kg/m3) 3.9 4.1 .25 PCF (68 kg/m3) 4.5 1.3 6.0 PCF (96 kg/m3) 6.5 8.3 2.7 3.8 1.7 10. Available in lengths from 36" to 120" (915 mm to 3048 mm).25 PCF (36 kg/m3) 2.1 1.7 3.7 10.25 PCF (36 kg/m3) 2.5 1.25 PCF (68 kg/m3) 4.25 PCF (36 kg/m3) 2.5 8.2 17.9 .0 15.1 .8 1.4 4.7 4.4 6.0 PCF (48 kg/m3) 3.0 PCF (48 kg/m3) 4.9 13.5 8.7 10.25 PCF (36 kg/m3) 3.0 PCF (96 kg/m3) *Available in widths of 24" (610 mm) and 48" (1219 mm).0 PCF (48 kg/m3) 3.9 2.8 1.0 15.25 PCF (36 kg/m3) 2. .3 6.0 PCF (96 kg/m3) 6.1 1.8 1.25 PCF (36 kg/m3) 2.25 PCF (36 kg/m3) 2.9 2.1 1.6 16.6 6.

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