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Surface prep for 2024-T3 human powered vehicle

Hi everyone,

I am a hobbyist working on a recumbent bicycle made of riveted/bonded aluminum -- mostly 2024-T3 .025" Alclad sheet with a few 6061-T6 components. The techniques used are all standard aircraft methods -- formed sheetmetal components are match drilled and prepped; pa room temperature cure 2-part epoxy is applied; and the components are assembled using rivets. My immediate intention is to build one for my own use and see how it goes.

What do you folks recommend for a safely applicable, environmentally friendly surface treatment protocol? My goal is corrosion protection for a vehicle lifetime <= 10 years and, if possible, adhesion promotion as a bonus.

The experimental aircraft community spans a wide range, from those who don't worry about priming at all (usually for 6061-T6) to those who conscientiously chromate conversion coat and zinc chromate prime each and every part. However, my situation is different from the experimental aircraft for a variety of reasons -- mainly related to the short intended lifetime of the entire vehicle and its low capital cost.

Thank you very much for any and all help. Peace,

Ihab Awad
Hobbyist - Palo Alto, CA, U.S.A.
2004

If you do not like the idea of chromate, consider type II sulfuric anodizing. If that is not an option, consider a phosphate coating. a good powder coat or a great wet paint should follow any of the above.

James Watts
- Navarre, Florida
2004