DIY Powder Coated Yeti Cups

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Introduction: DIY Powder Coated Yeti Cups

My wife wanted to buy a powder coated Yeti off Etsy for $65 dollars. I suggested we make our own with a harbor freight powder coating system ($52).

Step 1: Supplies

Powder coating works by electrostatically charging paint particles so they stick to metal objects. I created a base out of an electrical box extension, cover plate, and a piece of wood wrapped in foil. This is what you attach your GROUND wire to.

Step 2: How It Works

The footswitch controls when the tip of the spray nozzle is energized.

Powder coating uses very low air pressure (between 10-20 psi). I read online that a sweet spot is when you blow your hand the skin barley moves in.

Powder coating is extremely forgiving and easy to clean up. A simple cardboard box makes a great spray booth.

Step 3: Apply the Paint

This is my first time ever powder coating and the results were amazing. I found the angle of the sprayer made a huge difference (spray with the top of the hopper parallel to the ground).

The basic process is:

  1. Ground your object with the alligator clip.
  2. Step on the foot pedal to energize the tip.
  3. Point the nozzle of the sprayer about 8-10 inches from the object being coated.
  4. Squeeze the trigger to apply smooth even coats.
  5. When it's completely covered move over to the oven.

Step 4: Bake at 400 Degrees for 15-20 Minutes.

You shouldn’t use your kitchen oven to cook the paint. We got an old toaster oven and turned it on it’s size so the stainless steel cups would fit.

Step 5: Source for Cheap Paint

I called a local powder coating shop and asked to buy a few ounces of hot pink. They ended up giving me this whole bag they had leftover from another job.

Step 6: Finished Results

We had a lot of fun doing this, and with absolutely no experience got very good results. Highly recommended DIY project!

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60 Comments

Great idea! thanks for sharing. how hard is the coating? does it scratch easily? is the coating electrically insulating i.e. can it withstand 120VAC? If so I have a use for it.

Regarding powder-coating as insulation, it is plastic, takes a charge yet it's non-conductive. Metallics are the exception.

An average powder coating layer is .003" thick; once baked. As such several coats "should" provide insulation for 120 volts. I base this solely on 1000 volts ability to "arc" .250" (1/4 inch) to ground at atmospheric pressure. When in doubt/test it out.

you would have to spit at it in order to make 1KV arc over 0.25"

30KV/inch at 1 ATM. so .025" = 30/4= 7.5 KV. I made a few 'stun guns' so i have already gone thru these calcs.

sorry i made an error above so i am correcting it with a quote from

'Journal of Electrical Engineering'

"Normally air medium is widely use as an
insulating medium in different electrical power equipment as
its breakdown strength is 30 kV/cm"

Powder coating is fairly tough; it CAN be scratched but it takes a bit of effort. As for electrical insulation - I'm not sure I'd trust something as thin as powder coating for 120 volts. You might want to consider Plasti-Dip. I've used Plasti-Dip on tools to insulate the grips, but it's a fair bit 'thicker' coating than powder coating.

I did a search and found that if epoxy is used instead of just paint particles it has a dielectric strength of 1200V/mil using a 10 mil coating. so a 3-5 mil coating would be safe for about 500 Volts. it works up to 150C which is also plenty.

I'm not sure if I should be worried or intrigued by your specifications! Please do a follow up if this crazy project of yours comes to life!

by the way, thanks for the link. it says that epoxy powder coating is a great:
A typical high potential electrical test can be performed if requested, scanning all surfaces at twice the operating voltage plus 1kV. so i suppose this answers my question.

i just used 120V as an example.
i designed a transformer with 30 turns on the primary at 240V which is 8 V/Turn. the wires were made of copper strip. the secondary was for 200 amps also copper strip. i needed to isolate the windings from each other and tried a few layers of paint which did not work. eventually i used mylar tape and it worked. That crazy project of mine was eventually installed in an electric vehicle built for the Marines. I did not know about powder coating when I did it in 1995. it went into production and by now i dont know how many hundreds of this crazy idea were made. so u dont have to worry about anything. None of them ever failed.

Powdercoating is harder to scratch than the stainless. Much more durable than paint.