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Long term corrosion protection for a classic British motorcycle

October 24, 2012

Q. Hi
I have been reading your comments a lot and wanted to ask you questions since the first encounter. Let me explain my problem. I am pretty much in love with my motorcycle (Royal Enfield STD 350) and can't stand a sight of rust.

I ride my motor to work everyday and live close to the beach. Do you have any long term corrosion prevention recommendations ? Will the plan below work?

(A). ferrous parts,

1. Zinc plate the parts (Galvanize; I will get it done by a professional)
2. Use a putty/filler/joint compound to level out the scratches.
3. Sand the surface with a fine grit paper for better primer adhesion
4. Paint (or powder coat ?) a zinc chromate primer
5. Powder coat the final flat black layer

(B). Parts that get hot (exhaust, engine cover etc),

Steps 1 to 3 as above
4. Paint a silicone based heat resistant paint

(C). Aluminium parts,

1. Powder coat a silver/chrome layer

(D). Nuts,bolts, springs and washers

1. Galvanize

(E) Other ideas

I initially planned to weld a piece of zinc to the metal to be protected and connect with a copper wire (Sacrificial Anode / Cathodic protection). But that's going to be my last option as the chunks of zinc are going to be visually displeasing (Zinc is expensive as well).

Of course I will continue to spray WD-40 ⇦this on eBay or Amazon [affil links] every week on all mechanic fasteners. They have a new specialist product range that includes a corrosion protection product. But the specialist range is not available in India yet.

Note: As you suspect, I am confused and would like some help making the final decision.

Hazem Mammu
Hobbyist - Calicut Kerala India