My final drive was in bad shape as you can see from the as bought photos below:
I debated on powdercoating it and then decided not to as it might compromise the tolerances.
What else can I do but paint it?
The step by step process I took was:
1) strip and degrease
3) treat and clean the aluminum
5) fill any dents (or some of them)
6) sand out
7) etch primer - 2 coats
8) high build primer - 4 coats
9) sand out
10) spray high build where I sanded through to metal
11) sand out
12) color coat - 2 coats
13) clear coat - 4 coats
I didn't photograph every step of this incredibly tedious process but here's some of the shots:
Submerged in 140 degree alumiprep for 5 minutes:
Application of METAL2METAL filler:
Here's the paint line up:
And the final product, shot inside my makeshift paint booth:
And outside in the sun:
I had my camera on auto white balance so the color temps are different and the color therefore looks a little different.
As you can see, I decided to go with yellow to match the frame. It was either black, silver or yellow. Silver would never match the swingarm properly, black looks bad, so I had my paint shop custom mix me up a color and put it in a spray can. Took the guy 4 days to get it right and it's pretty dead on.
I'm letting the clear cure out for another couple of days before I rebuild it. I used a real deal 2-part urethane clear coat in a special one time use spraycan.