Frequently Asked Questions "FAQ's"

What is the difference between ZyCoat, ZyBar and ZyCor?

ZyCoat, LLC is the legal entity/company name. The web site is

ZyBar is the high temperature heat dissipation coating rated to 1600 degrees F (871 C) and over 2000 degrees F (1093 C) ambient temperature. ZyBar is the first high temperature heat dissipation coating that increases performance through reduced back pressure, provides outstanding corrosion resistance, color stability and is Do-It-Yourself “D-I-Y” low pressure paint spray gun applied. ZyBar outperforms ceramic paints, wraps and tapes and looks awesome under the hood.

ZyCor is the high temperature corrosion resistant coating rated to 1200 degrees F (649 C) surface temperature and provided in a “rattle can”. ZyCor is perfect for the home application if you just want your headers, exhaust or other engine components to look good under the hood!

What is ZyBar?

ZyBar is a high temperature thermal dissipation coating for headers, manifolds, turbos and exhaust. ZyBar provides: lower applied cost; increased scavenging performance (which equates to increased engine performance/torque/horsepower; color stability and corrosion resistance.

Is the primary focus on headers/exhaust?

Yes, ZyBar is focused on high temperature and harsh header, manifold and exhaust environment.

Is ZyBar for New Headers and Exhaust?

ZyBar can be used on new or old headers, manifolds and exhaust. The surface preparation and application instructions are exactly the same.

Is ZyBar patented?

Yes, ZyBar is patented technology.

What is the difference between ceramic coating and ZyBar?

Ceramic based coatings offer limited benefits however lack durability, corrosion resistance and require, excessive time and high cost of application. In many instances it is has taken customers over six weeks or longer to get headers back from ceramic coating houses. ZyBar, the only DIY product available in this category, saves you time and money and offers excellent engine performance benefits. ZyBar costs less than 1/3rd the amount of ceramic coating. Specific ceramic coatings also have a linear expansion problem when bottling. This creates a buildup of pressure in the package and requires a very delicate “burping’ of the container to prevent projecting the material. This expansion issue does not occur with ZyBar.

How does ZyBar compare to the thick paint on products like POR and Eastwood thermal coatings?

Customers have provided us their impression of ZyBar compared to other coatings they have used – the competitive products like POR and Eastwood are “okay” but do not do a very good job of standing up to heat above 500 degrees F (260 C). ZyBar is formulated to withstand the harsh, high temperature exhaust environment over 2000 degrees F (1093 C). ZyBar thrives in excessive heat. ZyBar is a low viscosity, high solids coating which sprays and atomizes easily in a standard 30 psi spray gun. ZyBar flows incredibly well “nearly like water” through a spray gun, stated several users. ZyBar is applied in 1 – 1.2 mil (.0015 - .0025) coating thickness which covers a much greater surface area versus the thick/high viscosity materials such as POR15, Eastwood or other coatings. ZyBar coats easier than traditional exhaust paints which must be brushed on.

Are there color options for ZyBar?

Yes, ZyBar is available in four bold and beautiful colors. Bronze Satin, Midnight Black and Cast (Medium Gray) and Aluminum (Silver).

Is ZyBar manufactured in the USA?

We manufacture the product in the Midwestern United States!

Is anyone using ZyBar in other areas besides headers?

ZyBar is new technology. Customers have sent us fantastic testimonials from coating headers, turbos, downpipes, intakes, engine blocks, piston heads, intercoolers and trim components wheels, mirrors and door handles. Click Thermal Exhaust Manifold Coating & Header Paint – Zycoat or Visit and scroll down to “ZyCoat Reviews”. Users and applications have grown exponentially on on-road and off-road tracks and fuel systems. We would love to hear from you after using our ZyBar high temperature thermal dissipation coating.

Are you talking with any OE manufacturers?

Yes, we are discussing ZyBar application and use with several aftermarket OE and component manufacturers.

Has ZyBar been tested on diesel?

ZyBar is proven to perform on manifolds and turbo housings on diesel drag and diesel pull trucks, the most extreme temperature diesel environment.

Is thermal dissipation different than sound deadening?

Thermal dissipation is different from sound deadening. Thermal dissipation material such as ZyBar uses micro surface technology to coat into the metal through fissures, microscopic cracks, pores and voids allowing the metal to transfer heat, or pass on the heat to the unrestricted area (air) at an accelerated rate versus untreated metal. Untreated metal in a tube allows the heat to build up around the perimeter of the tube restricting air flow, allowing heat to radiate to the exterior of the tube.

Sound deadening is the mass based surface technology that uses the principals of mass, adhesion and conformance to convert vibrational energy into heat. The sound deadening rubber in the material absorbs this heat. The foil constraining layer is a backstop which reflects any excess heat, passing through the rubber, back into the rubber.

Are you stocking in Olathe, KS?

Yes, all shipments of ZyCoat, LLC products will occur from our facility located in Olathe, Kansas.

Other than exhaust, what can ZyBar be used on?

ZyBar can be used on all gas, diesel, alcohol and top fuel engines exhaust, headers, manifolds, turbos, intakes, piston heads, intercoolers and other components subjected to elevated temperature. Automobiles, Trucks, Boats, Motorcycles, Off-Road vehicles and Semi Trucks the focus of ZyCoat, LLC today. ZyBar can also be applied to bolt on heat shields and heat barriers to better dissipate heat.

What is the difference between Powder coating and ZyBar?

Powder coatings do not survive above 500 degrees F. Powder coats burn off in a very short period of time and offer no performance benefit to the engine. ZyBar is formulated to perform far above the harsh automotive temperatures and environment. ZyBar was proven to increase engine performance in third party dynamometer testing.

What is the difference between Silicone coating and ZyBar?

Silicone based coatings do not last under the extreme temperature and harsh conditions in exhaust applications. Silicones burn off in a very short period of time and offer no performance benefit to the engine. ZyBar is formulated to withstand this harsh environment and was proven to increase engine performance in third party dynamometer testing.

Where can I find application instructions for ZyBar?

ZyBar Application Instruction video is available for your viewing at then Click on “Watch Application Video” or click on ZyBar_Application_Instructions_2020.pdf To download and print a copy of our written application instructions.

Are glass or glass beads adequate media for surface preparation prior to coating?

NO, glass beads are “polishing” media and NOT etching media. Under no circumstances do we recommend this method for adequate surface prep. The metal surface must be etched with 100-120 grit aluminum oxide or garnet sand media.

Click here for our ZyBar Application Instructions: ZyBar_Application_Instructions_2020.pdf

Do you have any advice regarding type of blasting cabinet we should buy?

We do not have a specific brand recommendation as there are several excellent new and used brands of cabinets. However, we recommend that you factor the following points into your purchase decision:

  1. Size of the area inside the cabinet and the ability to get parts inside and out easily (opening).
  2. 2. Also, IF the part to be blasted will be combinations of used/rusty/grimy and new metal; we advise:
    1. a. Old, rusty or grimy parts can contaminate the blast media which then gets re-used. Follow blast media or cabinet manufacturer recommendations for clean out and media replace consideration. Contaminated media can be impinging into the next part(s).
    2. b. IF you plan to blast multiple parts between SS (“Stainless Steel”) and CRS/HRS (“cold rolled steel/hot rolled steel), this can also be a source of contamination. We recommend following the media and/or blast cabinet instructions for clean out and media replacement.
  3. 3. Confirm operation of oil/moisture separator for the compressed air line feeding the blast cabinet. A poor oil/moisture separator can contaminate the media if water or oil is getting mixed into the nozzle spraying the media.

How do you prep inside the tubes?

We recommend blasting aluminum oxide or garnet sand or media that is designed to etch metal (100-120 grit) through all openings of the tube for several seconds (minimum of 60 seconds) on each tube opening while turning the tube to allow the media as much contact on the inner circumference of the tube. We then recommend forced air through each tube opening to remove dust or debris.

Can ZyBar be blasted off?

Yes media blasting can remove ZyBar.

Stainless surface preparation - media blasting - will it scuff it up?

Yes, scuffing will occur, however ZyBar will bond to the properly prepped stainless steel.

If I have ceramic coated headers does media blasting remove the ceramic paint?

Yes, we recommend using aluminum oxide or garnet sand or any other media designed to etch metal (100-120 grit) specifically for the very best in surface preparation. This media will remove the ceramic from the headers and then you are set to apply ZyBar.

How does a D-I-Y person media blast?

We recommend taking your headers to your local town automotive paint shop or powder coater. The approximate cost to have a set of headers blasted? The average cost to sandblast a set of headers should not be more than $30-$50 per set depending on size.

Do-It-Yourself enthusiasts can purchase a relatively inexpensive portable gravity feed abrasive blaster. We do not recommend one-brand versus another. We have used the Black Bull SFSB90 gravity feed blaster which is easy to use and connects to your shop compressed air lines.

Can Scotch-brite or Sand Paper be used to prep the surface?

No. This method of surface prep does not remove contaminants. We recommend media blasting the surface as described in detail in our Application Instructions. YOU MUST REMOVE ALL SURFACE CONTAMINANTS prior to applying ZyBar.

Wear gloves whenever handling the component after media blasting to avoid leaving hand oils on the surface of the cleaned part. Once the component has been media blasted we recommend applying ZyBar immediately to the component.

Failure to follow this process can allow the contaminants on the surface to be ground into the pours in the metal. When the component is then coated – post cure these contaminants will outgas and cause the coating to “bubble” or delaminate from the surface.

How long after prepping the component surface should I apply ZyBar?

We recommend applying ZyBar as soon as possible after the surface preparation steps are complete. Leaving the components for a significant period of time after prep and prior to coating increases the risk of surface contamination, dust build-up, rust, oxidation all of which can affect the coating performance.

Do you need to thin ZyBar prior to use?

ZyBar requires no thinning or dilution. ZyBar is ready-to-use. Each can is packaged for individual use as defined in the application instructions. There is no catalyzing required with ZyBar.

Is there a big increase in horsepower with an in/out coating?

During our dyno testing in April we tested long tube headers coated outside only and inside & outside coated. We experienced a 1.2% gain in horsepower and torque consistently between 4000 and 5700 rpm when coating was both inside and outside the headers versus 0.4% horsepower and torque gain on headers coated on outside only. We experienced a consistent performance gain when both the inside & outside of the headers were coated.

How do you know that you are applying the coating “thick enough”?

ZyBar technology requires only 1.5-2.5 Mil thick coating (.0015 - .0025). On a media blasted surface if you see the color change from the “gray” to the ZyBar color you have likely applied enough material. Since ZyBar will bond to itself you can re-coat any area you feel was light by simply passing the spray gun over that area on two passes (in other words from right side to left of area and then back again). This is especially important with ZyBar-Aluminum as that color is not significantly dissimilar to the media blasted surface color.

Do you spray it on?

We recommend using a low pressure (28-30 psi) paint spray gun.

What size can do I use on different sized components?

The rule of thumb to follow is:

One (1) eight ounce bottle will coat a set of small block headers or set of “Shorty” headers coated inside & outside.

One (1) 4 ounce bottle will coat a turbo housing or a 4 cylinder stock manifold coated inside & outside also a set of 8 cylinder piston heads.

One (1) sixteen ounce bottle will coat a set of long tube headers inside & outside.

One thirty two (32) ounce bottle will coat an entire exhaust.

Assume one (1) ounce per 18” of 2 ½” standard exhaust tube.

How do you coat inside the tubes or headers?

For components such as tube or headers we have found the best method to coat the interior with ZyBar is:

  1. Utilize a flexible hose/wire with jaw clasp at one end (aka Tool Grabber).
  2. Ball up non-lint clean rags and use jaw clasp to hold rags.
  3. Dip the rag into ZyBar and allow rags to soak up coating thoroughly.
  4. Dip the rag into ZyBar and allow rags to soak up coating thoroughly.
  5. Pull the rag ball through both ends of each port on tube or header
  6. Dip the rag as needed to keep rag wet with coating (very light drip)
  7. Hang the component and allow the coating to dry
  8. Use a non-lint rag wetted with MEK, Acetone or other like solvent to remove any drips or excess coating that should drain out of the tubes
  9. Due to the difficulty with geometries of the component it will not be possible to ensure 100% consistent coverage. We have found this process to be the most effective method for ZyBar.
  10. DISCLAIMER: Good coatings do not overcome bad surface preparation or application.

An alternative that we have heard others use is the “cap & slosh” method. For components such as tubing which cannot be easily sprayed, ZYBAR can be applied in a manner which flows over the surfaces.

To do this:

  1. Prepare to pour ZYBAR in one end by sealing off all other openings except the planned point of coating entry. Sealing can be done using commercially available silicone plugs, tape or other non-absorbing materials.
  2. Pour a suitable amount of coating material into the unsealed opening.
  3. Then seal the “pour” opening
  4. Gently rotate the tubes/manifold to permit the coating to flow over all interior surfaces.
  5. Due to the wide range of manifold geometries and configurations, fully ensuring that adequate coverage has been achieved is not possible. Thus, the greater the number of angles of rotation that are used, the greater the probability of full coverage.
  6. Drain the manifold or tubular item. NOTE: Be sure to pour out the coating used on the inside surfaces into a second container for disposal later. Cross-mixing of the “virgin” ZYBAR can cause problems.
  7. Just as in the application of the coating, it is important to fully rotate the pipe/manifolds in numerous angles so as to avoid trapping any coating in recesses. If this happens, the added coating thickness in these recesses will result in the coating “mud-cracking” once it cures.
  8. Hang the internally coated part so as to allow for continued uniform draining, until it is dry to the touch.
    Use a lint free cloth or toweling wetted with MEK or similar solvent (No mineral spirits or naptha solvents) to remove any coating that has gotten onto the exterior surfaces, before it dries.

    Note: Saving the leftover material in a sealed container for future use is not recommended.

I Missed a spot of coating or I scratched it in install - what do I do?

The four-ounce bottle is also perfect for touch up. Once Zybar is cured you can apply a second coat over the surface. This is a unique benefit of ZyBar vs ceramics and other less efficient coatings. The 4 oz. can is designed for touch-up and finishing purposes. We suggest wearing gloves and not touching the area with your hands, scotch-brite to rough up the area that you are touching up. Then re-spray or use a very small brush to apply Zybar to the affected area. It is important to follow the step by step application instructions for mixing/stirring prior to use.

Should applicant wear gloves?

It is imperative that anyone using Zybar read and follow both the Safety Data Sheet and Application Instructions which are readily available at

Gloves and proper Personal Protective Equipment (PPE) should be worn at all times during handling, use, and application and cleanup of ZyBar. It is also important to wear gloves when handling the components that you will be coating, especially after surface preparation.

Can you put ZyBar over something that is already ceramic coated?

We do not recommend this. Previously ceramic coated parts should be media blasted according to our application instructions.

If you nick a corner after cap/slosh, how do you touch up?

We offer the 4 oz. size specifically for touch up of these areas. The benefit of ZyBar versus other heat coatings is you can apply a second coat of ZyBar over the first coat of the same. ZyBar is formulated to bond to itself.

Is there an insert for where to go to get application instructions?

There is no “insert”. Application instructions for ZyBar are readily available on the box label and can also be downloaded from ZyBar_Application_Instructions_2020.pdf

Can header or exhaust be bolted on after 120 hour air cure?

We recommend bolting on components only after cure is completed as explained in the cure section of application instructions. If you chose air cure – the chemical resistance of ZyBar is not fully recognized until the component goes through its first “in-service” cure. Once air cured, carefully bolt on the component and allow the engine to idle for 12-15 minutes. This will allow the coated component to ramp up to temperature. A final “cure” step is once the coated component surface temperature reaches 625 to 650 degrees F the component will give off a white opaque smoke. This smoke will last 30-45 seconds and then end. This is the “final” in service cure step.

Is it flexible?

Yes, after cure we have bent panels 45 degrees with no cracking or delamination.

How will a DIY customer know the air cure is done?

When 120 hours have expired from completion of applying the coating.

Higher humidity? How will that affect the air curing time?

Excessive humidity (ie >75%) will slow the cure process.. We would advise that you follow the application instructions including ambient temperatures for storage and cure.

If someone puts in a kitchen oven to cure, what will happen?

We do not recommend the use of non-commercial rated oven of any kind. We adamantly do not recommend using a “kitchen” oven for curing industrial coatings.

What solvents can be used for cleaning spray guns and other equipment used in application?

We recommend using TBac or Acetone for cleaning after application of ZyBar. Follow the equipment manufacturer instructions for cleaning. We do not recommend use of naptha based solvents or paint thinner. DO NOT USE MINERAL SPIRITS FOR CLEANING - THIS IS A NAPTHA BASE SOLVENT.

Cleanup the spray gun? How to? Is it possible?

As noted in the installation instructions we recommend running approved solvent through spray gun to clean out for next use. . We suggest using acetone to clean out the spray tool immediately after use.

Is there a separate part # for case vs individual skus?

Single part numbers are used for individual bottles. Same part is used for case packs with the quantity defining a case. Each bottle and case will carry a unique serial number for lot traceability purposes.

What’s the shelf life?

12 Months from date of shipment providing the bottle seal is not broken.

If stock passes the 1yr shelf life, can they return?

No – the key is to use the product within this shelf life period.

How does the customer know the date of production?

Each bottle contains a unique serial number. If there is any question our technical service department can assist. ZyBar warranty is one year form date of shipment providing bottle in un-opened.

As a distributor, do we send a customer to you if they have a problem?

ZyCoat, LLC’s customer and technical service department (913) 599-2600 is available to answer questions that may surface. Hours are 8AM – 5PM M-F Central United States Time. You may also email our Technical Service department

Would you put on turbo-type housings?

Turbo housings, super charger housings, water pumps, and intakes are additional components that coated with ZyBar.

How do jobbers/dealers/customers get listed on the ZyCoat dealer locator?

We will work through our Wholesale Distributors to receive jobbers/dealers for placement on dealer locator and we will also set up jobbers that purchase on a direct basis. IF you wish to be added to our locator you can call our office M-F 8AM-5PM Central Time (913) 599-2600 or email us at

Did ZyBar get tested for under hood heat reduction?

We have tested radiant heat above the top center of headers during dynamometer testing. We did test the reduction of surface temperature and combined with the radiant heat reduction measured to a 40% reduction in under hood temperatures. Numerous customers have also expressed significant heat reduction in under-hood temperatures as a result of ZyBar coated components. See our Technical Data Sheet that illustrates this test data.

What testing has been done to confirm performance of ZyBar?

Extensive laboratory testing has been done throughout to confirm the ZyBar performance over the four and one-half years of ZyBar development. In addition, real world testing was done on at Karl Performance, Ankeny, Iowa on their engine dynamometer on a GM Crate 604 engine.

Can I return ZyBar once it has been opened?

ZyBar is packaged with two levels of seal. The first is a bottle seal that compresses into the can opening. Once this cap is lifted or even slightly separated from the bottle the ZyBar cannot be returned. The second seal is the white ring around the underside of the screw on cap. This provides a second air-tight seal.

Frequently Asked Questions "FAQ's"

What is ZyCor?

ZyCor is a high temperature corrosion resistant coating that is packaged in an aerosol spray can.

What is the difference between ZyCor and ZyBar?

ZyCor is a high temperature, corrosion resistant coating that maintains it color at automotive engine operating temperatures. ZyCor is applied in either one step or two. ZyCor Primer is the first step. ZyCor Primer is both a standalone coating or is used as a Primer coat for ZyCor Color Coats. *** You do not apply ZyCor Color Coats without the ZyCor Primer base coat. ZyCor Primer is a flat Medium Gray color.

ZyBar is a high temperature heat dissipation coating that improves the performance and efficiency of the component to which it is applied (ex. Headers, manifolds, turbos and intakes). ZyBar improves horsepower, torque. ZyBar also provides corrosion resistance and color stability. ZyBar must be applied using a 30 psi primer/paint spray gun. ZyBar is a single component, standalone coating and does not require any primer.

Do you have to prep the component surface prior to applying ZyCor?

Yes, the component surface must be media blasted using 100-120 grit aluminum oxide or garnet sand. For more information read the ZyCor application instructions which are readily available at

Do you coat the inside and outside of the component with ZyCor?

ZyCor is applied to the outside of the components. ZyCor is designed to provide outstanding corrosion resistance to the outside of the component. For exhaust tips you should coat the interior that will be visible when the component is installed.

How does ZyCor compare to other high temperature paints on the market?

ZyCor outperforms the other high temperature paints available in today’s market. ZyCor has been tested to perform up to 1200 degrees F surface temperatures. ZyCor provides better corrosion resistance and color stability. You get the performance you pay for with ZyCor. Industry veterans have told us the other aerosol paints simply don’t last. We received the following direct comments from numerous industry veterans regarding other brand high temp paints: “They burn off”, “They crack and flake”. “I painted my headers and drove to the car show. When I arrived the paint had completely burned off and I had to coat them again.”

What is the shelf life of ZyCor?

ZyCor’s shelf life is 12 months from the date of shipment from ZyCoat, LLC.

Can I return ZyCor that has expired the shelf life?

No, once the date is expired we will not accept the return of the product.

If I use a small amount of the ZyCor and still have product in the aerosol, can I use it in the future?

Yes provided the reuse is within the shelf life of that can. After use, we recommend turning the aerosol can upside down and spray the aerosol to clear the line of the coating. If the coating cures in the spray nozzle it will be not be usable.

Do I cure the ZyCor Primer prior to applying the ZyCor Color Coat?

NO, the ZyCor Primer must not be cured before applying the ZyCor Color Coat. Spray the ZyCor Primer and allow 8 hours for the Primer to set, then apply the ZyCor Color Coat. Cure the ZyCor Primer and ZyCor Color Coat together.