How do you finish your projects?

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I've seen many great projects in this forum and am just getting started on several of my own - the ubiquitous welding table, mig and tank cart, some shelf standards for the workshop, a metal rack to hold all of the Plano boxes of nuts and bolts, etc.Ignoring the welding table for the moment, what is the common method for protecting the item from rust and make it look reasonable? Reasonable in this context being defined as “looking at it doesn’t bring back bad memories” or “I should have …” thoughts and the wife will not object. It does not mean perfect or concourse condition. The spectrum would seem to go from powder coating to nothing at all.  So I’ve got a few questions about the process others have done.Does anyone use powder coating and how expensive is it? Like a mig and tank cart.If painting it yourself, do you do a lot of work on surface prep – slag removal via sand blasting, sanding, wire brush, etc. or just paint right over the welds and the rest of it and assume the paint will stick.Do you use a primer coat and then a color coat or just the color coat?Rattle can – spray gun – roller - ????Does your process differ if it will be used outside rather than inside?And finally, any favorite “silver bullet” coatings? You know, the magic “Looks spectacular but absolutely no effort” product, just like in the marketing brochure?Thanks,Arvid
Reply:I always have great results with Rustoleum Professional grade paint. Typically comes in the gallon size and has a checkered pattern around the top edge of the can.  roll or brush onApplying process:  If we're talking about items like cabinets / shelves/ tables / carts or other shop items that will get beat up......-Wire brush all welds-clean the rest of the metal with either alcohol (trichorethylene), acetone, or chlorinated brakleen.-I rarely prime items that will just get beat up in my shop (although priming does typically allow you to get away with only one coat of paint. without primer the paint sometimes shows through or applies on streaky.)-On heavily rusted surfaces: chip away the rust and wire brush, but usually I don't bring it down to new metal.  I have good results painting right over flash or slightly rusted items.Powder coating:I know of people that have invested in powder coating guns and a second oven.They have good results, but the finish is sometimes brittle and chips easily.  Professional powder coating is great, produces nice results, but can get costly.Again, if we are just discussing the items I listed above don't waste your money.....paint is quick and looks good.  my 2 cents-Graham-Mechanical EngineerAutosport Mechanic/Fabricator
Reply:Mill scale seems to be my most popular finish lately followed by a natural patina that nothing short of time itself coupled with unique molecular reactions can apply (sometimes called "rust" by the uninitiated).  For shop projects, shiny, painty powdered whatever just makes it look too "store bought" to my eye.  Just 2 cents.
Reply:Originally Posted by arvidjDoes anyone use powder coating and how expensive is it? Like a mig and tank cart. Arvid
Reply:Thanks for the reply's. Though most of them actually involve work  the recommendations will certainly same me from "learning by doing it wrong" several times.
Reply:After years of trial and error, I've determined that no project is ever finished.They just keep going on and and on and on and......There are no small projects