Anyone in sheet metal fabrication knows the frustration: you rivet two movable sheet metal parts, only to find the powder coating scratching and chipping at the joint during relative movement. Not only does this ruin the part’s appearance—it also compromises rust resistance, defeating the purpose of the coating entirely.
After testing a few approaches, we’ve landed on two simple, effective fixes to keep your powder coating intact, focusing on creating a tiny gap between the two parts to eliminate direct friction.
The first go-to solution: add a 0.5mm plastic or metal shim between the two sheet metal pieces before riveting. This thin barrier keeps the parts from rubbing against each other, preserving the powder coating and maintaining the intended mobility of the design. It’s straightforward, cost-effective, and works consistently for most applications.
We also experimented with a temporary hack: placing a 0.5mm card between the parts during riveting, then removing it after the joint is secure. While we noticed minor friction during card removal, the end result is a 0.5mm gap that prevents long-term rubbing—perfect for projects where a permanent shim isn’t ideal.
Small gaps make a big difference: no more unsightly chips, no more rust risks, just clean, durable sheet metal assemblies that perform as designed. Have you tried a similar trick, or do you have another hack for this common fabrication headache? Drop a comment below—let’s learn from each other!
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