I once powder coated a set of wheels for a guy in my oven here at home and this crevess in the picture where the center of the wheel gets pressed into the wheel hoop then welded on the back side made it a bitch to PC. The wheels were used so there was some rust in the crevess on all five wheels. I grit blasted all 5 wheels as good as I possibly could in a very powerful pressure pot type grit blaser with good Aluminum Oxide grit. No matter how long I pointed the gun at the crevess I could not get all the rust deep down in the crevess out. There was only a very small amount you could see, very small. So then I used a sharp pick and scraped and scraped and scraped to get as much as possible out.
When I did the first wheel it came out awesome.......except for that crevass. I guess from the rust, not really sure why but there was bubbling of the powder coat all around that crevass. THAT part looked like shat. I was pissed

. So I called the guy and said the only way I could think of to fix that would be to weld a full bead around the wheel in that area, then coat it. Said it would fill in the area and give the PC a nice surface to bond to. He didn't like the idea of a weld being seen there. So I said I could bench a full radius and blend the weld out so it is countoured and is smooth.
He said that would be cool, and could use the first wheel I PCed as the spare wheel. A beauty ring would still NOT cover that area up. He said he was going to run beauty rings on his wheels. So I proceed to weld all the wheels up. Then started benching the weld with a 3/8 diameted carbide derubing bit. Like whats used for porting a cylinder head. MY GOD that was one of the hardest things I have ever done

. It tooks hours and hours to do just one wheel. Went thru three burr tools bits at 8 bucks a pop. I PCed one wheel and it came out bitchin. But considering I was only charging $125 bucks for the set of 5 wheels I was losing my ass BIG TIME
. It was my first set of wheels so I thought I would go cheap just to try it out.
I was done. Was tired as hell of deburing and my hands hurt like hell from deburing for hours and hours at a time. I would be covered in super fine metal shards of steel. It was horrible. A HUGE learning curve to say the least. I ended up deruring two wheels, powdercoated one with deburing, and of course the one without welding. Welded all of them as I said. Gave him back his wheels and his 1/2 half payment he gave me up front. Gave him the Yellow powder coat powder I ordered just for his wheels and said "dude, your on your own".
I hated the fact I could not finish them for him. He actually totally understood. He said he knew it was gonna be tough, but he said no problem, he would figure it out. I felt really really bad but it was just not something I was going to finish. I would have had 2K of time invested in those wheels for a crappy $125 bucks. No way, Hell no. If he would have just let me weld them and PC, it would have been all good. Never did a set of wheels again and never will
