1. Skipping or Rushing Surface Preparation

Why it’s a problem:

Surface prep isn’t just a formality, it’s the foundation of a long-lasting bond. Failing to remove grease, rust, scale, or old coatings will prevent proper adhesion and may cause premature failure or flaking.

What to do instead:

Always follow the manufacturer’s prep instructions. For ZyBar, we recommend outgassing in oven prior to blasting, then abrasive blasting with Aluminum Oxide creates a clean etched profile finish. Avoid using solvents that leave residue. Time spent prepping is time saved avoiding rework.

 

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2. Applying to a Contaminated Surface

Why it’s a problem:
Even if a part “looks” clean, it can still contain oils, moisture or embedded contaminants that interfere with bonding and curing. This is especially true in humid environments or shops where silicone sprays and lubricants are used.

What to do instead:
As soon as possible after media blasting apply ZyBar coating. Avoid touching cleaned parts with bare hands to prevent transferring skin oils. If you're spraying in a shared shop, watch out for cross-contamination from impurities in the air.

 

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3. Over-Applying the Coating

Why it’s a problem:

More is not better. Applying too much product in one coat can lead to solvent trapping, runs, poor curing, cracking, or reduced heat dissipation. Excessive thickness can cause the top layer to skin over trapping solvents underneath. This does not allow the solvent portion of the formula to flash off. When the component is subjected to heat – the solvent “pops” and lifts the coating off the component. It can also extend dry.

What to do instead:

Apply multiple thin, even tack coats, allowing the appropriate flash time between each one. With ZyBar, less is more—a uniform 1.0–1.5 mil thickness is all that’s needed for maximum performance.

 

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4. Not Curing the Coating Properly

Why it’s a problem:

Skipping the curing step or using the wrong method can leave the coating soft, under-bonded, and unable to withstand high temperatures. Improperly cured coatings may off-gas, discolor, or flake off when heated in real-world conditions.

What to do instead:

ZyBar can be cured in two ways:

• Oven Cure: Once the coating application is done and the part is “dry to the touch” (allow a minimum of 45 minutes post application for the solvents to completely flash off). The part can now be placed into a paint curing oven at 450°F for 120 minutes.

• Air Cure: Allow the part to continue to be at ambient temperatures of 70 to 90°F for approximately 5 days (120 hours), the coating at this time is ready to be put into use. iF air cure method is used the coating will not have its elevated hardness or chemical resistance until it sees heat.   Carefully handle and install the component and allow the engine to idle for 12-15 minutes.   This will allow the coating to “in-service” cure.   

NOTE: After the coating has cured either by air or oven and once placed in service, the first time the component surface operating temperature reaches 650 degrees F it will likely cause the coating to smoke for a short period of time (20-40 seconds), this is the normal final stage of the cure process.

Always refer to the technical data sheet for the correct process.

 

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5. Spraying in Poor Conditions

Why it’s a problem:

Environmental factors—like excessive humidity and airflow—can significantly affect coating application. Excessive humidity (>75%) can lead to blushing, while low temps (<40 F) can increase dry time or prevent proper bonding.

What to do instead:

Spray in a well-ventilated, dry, and temperature-controlled area. Ideal temp is between 60°F and 85°F, with humidity below 70%. Use a clean HVLP gun, tip and follow recommended PSI settings.  Detailed application instructions are available at ZyCoat.com 

 

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✅ Bonus Tip: Always Use the Right Equipment

Using the wrong spray gun or nozzle size can cause uneven coverage or wasted product. ZyBar is designed for HVLP spray systems, and our team is happy to provide guidance on the ideal equipment and settings.

 

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🏁 Wrap-Up: Good Application = Great Performance

Performance coatings are all about protection, durability, and efficiency—but none of that matters if they're applied incorrectly. By taking your time, following best practices, and avoiding these common mistakes, you’ll ensure your components are protected and performing at their best.

Have questions about prepping or applying ZyBar? Contact us ZyCoatTech@gmail.com or call (913) 599-2600 (M-F 8AM – 5PM Central Time) —our tech team is ready to help.

 

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