Paint it Black: Evotech Performance's Powder-Coating Process
Why do Evotech choose to powder-coat their motorcycle parts?
Take a guess, just roughly. How many products do you think are currently listed for sale on the Evotech Performance website? A thousand? Ten thousand? The number is actually around 29,000. And it is going up. Daily. And what do over 95% of these parts have in common? They all have Evotech’s now iconic matt black powder-coated finish.
Powder-coating is an art which Evotech Performance have been perfecting in-house for the last 20 years. The benefits of powder-coating our products, rather than just painting, are substantial. When properly sprayed and cured, the powder-coat finish creates a strong protective layer, keeping each part in use for longer and holding damaging corrosion at bay. Aesthetically too, the benefits are clear. The textured black coating creates a discreet, factory finish with EP parts melting into the body of the motorcycle, just as if they had always been there.
Evotech's powder-coating process
As with every production machine across the Evotech plant site, the powder-coating process follows the mantra of having the highest level of quality for our motorcycle parts. Supplied by Haviland Limited from Derbyshire, the EP system has been installed following our bespoke requirements. Using a mechanised hanging rail track, with wash systems, ovens and painting booths, the powder-coating machine covers over 240 square metres.
A visit to Evotech’s traditionally named ‘paint shop’ is a calm release from the noise of the production floor. From the energy of the sheet metal punching, or the power of the high-speed lathes, the painting area slows to run with the metronomic clicking and clacking from the continuous conveyer. The whole area is meticulously timed to 3-minute intervals. From 3 minutes per flight bar in the phosphate wash to 18 minutes for 6 flight bars in the first oven, it literally runs like clockwork.
Before any part can receive their final covering, each first needs to be hung onto the flight rails (designed in-house, obviously), evenly spaced and thoughtfully placed to ensure the optimal coverage of powder. From here, the trip around the hanging monorail can begin.
The first stop is a 3-phase wet wash. Arriving from production with oil, swarf and dirt on the surface, the EP parts head to the showers. To start with is a jetted combination of degreaser and iron phosphate – which prepares the surface with microscopic etching, giving an improved key for the powder to stick to. A basic tap water shower washes away the initial chemical treatment before a demineralised water completes the process.
Once a batch of 6 flight rails has been through the wash, they jointly head to the first oven of the day, spending 18 minutes at 100-150 degree heat to dry off all moisture.
Out of the oven and along the conveyer, each flight bar of EP parts then reaches the powder-coating zone. Treated one at a time, the flight bars are turned as required by the expert sprayers to ensure a consistent coverage of the matt, black coating. As the powder is expelled from the spray gun, it is given an electrostatic charge which attracts it to the closest grounded (or earthed) object: the thoughtfully hung Evotech motorcycle part. Electrically charging the powder-coat gives an improved level of control and efficiency in the direct application, minimising waste and creating a smooth, uniform finish.
Is powder-coating at Evotech fully mechanised?
When the powder-coat is applied, the knowledge and skill of the Evotech team is vital. Trusted Painter Dave Taylor has over 20 years’ experience of powder-coating the EP parts. Confident in his skill to achieve the goldilocks level of powder-coat application (not too thick, not too thin), Dave makes quick work of spraying each part, with even coverage, an eye on build-up on insertion points or corners and powder ‘wrap around’. Now leading the powder-coating team of three Evotech staff, Dave oversees the constant throughput, ensuring quality and precision of powder-coating meets the premium level EP products deserve.
How is the powder-coating process finished?
With the matt, black texture now in place, the conveyer travels on – this time to the second, hotter oven. Again, flight bars enter in groups of 6 for improved efficiency. With each part spending at least 10 minutes at temperatures of 200 degrees, the coating is cured, sealing to form the hardened protective shell.
Now fully powder-coated, the Evotech parts rest and cool in the post-treatment area. Taking over 30 minutes before cool and dry enough to be handled, removed from the flight bars and quality checked.
From the large radiator guards and tail tidies to the very small mirror extensions and pillion removal brackets, each Evotech Performance part that crosses the threshold of the paint shop receives the same high level of attention. Making sure that every powder-coated Evotech Performance part has EP’s premium discreet styling and long-lasting durability.
What happened when Tarran Mackenzie and Jason O'Hallaran spent their day trying their hand at skills including powder-coating at Evotech Performance? Watch the Evotech Racer to Maker video.