LocostUSA.com

One of the guys at work asked me to repair his powder-coated roof rack. It was powder-coat alright, with not much metal left behind.

_________________
The Lethal Locost
The Lethal Locost 2 - Even More Lethalerer

That's what I was talking about! If anyone watches "Wheeler Dealers" on TV, track down the episode where they restore a high-end exotic TVR. The tubular space-frame was powder coated at the factory when the car was built, and looked pretty good when they first got it up on the hoist.

Once they started poking around, they discovered there was no frame at all left - just powder coat tubing, filled with a shale of rust. They had to acquire an entire new, custom frame for that car.

_________________
Scratch building, at continental-drift speed, a custom McSoreley-design framed, dual-Weber 45DCOE carburated, Zetec-engined, ridiculously fast money pit.

http://zetec7.webs.com/

I used 3/4" .095 tubing and haven't had any issues after 50K miles. In the failures I've seen, the lower A-arms departed somewhat from the book design, the most common problem being stress risers from the shock mounting plate.