I started on my window frames yesterday, and am wondering if I will be able to powdercoat them with the surface pittting caused by rust. I am hesitant to try to fill with metal, because of warping but could I get away with a body filler product with metal particles in it ? I'm going to contact a coating shop Monday but curious what others here may have done.

Tom

 

There is a filler material suitable for use under powder coating, but I forgot what it is called. Just found it, called high temp lab metal. http://www.alvinproducts.com/Products/Products.asp?id=2
There is also a low temp material that some have had sucess with for filling pits in pot metal castings before rechroming, Muggyweld?

 

For very minor pitting, powdercoating may fill that. It's pretty heavy stuff and flows out smooth, to a point. Big pits, probably not so good. You'll have to fill and paint, the old fashioned way.
Chroming, that's tougher. You really need a clean and smooth surface for chrome to work good. They can fill minor imperfections with copper prior to the nickel and chrome top coatings, but too much will build up in places you don't want it to, and cause fitment problems at assembly.
Talk to your platers/coaters next week, and report back what they said. Different shops may have different remedies for your situation. I'd be curious to know what they tell you.

 

I've used JB weld several time now and it works great.

 

I dropped my vent frames off for powder coat and my hood lever off for chrome, hope to have them in a week.