Refinishing galvanized firewall

[Ed Haywood]

I am doing a bare frame restoration of my Decathlon fuselage while the engine is off for overhaul. Looking for suggestions on how to maintain the finish and appearance of the galvanized firewall.



Firewall has been removed from the aircraft and is bare, which opens up some possibilities, including:

1. Regalvanize - hot dip
2. Electroplate
3. Powdercoat
4. Paint
5.. Clean and leave alone
6. Replace with stainless

Thoughts?

 

[Dana]

Cold galvanize... comes in a spray can.

 

[Gary Ward]

I am doing a bare frame restoration of my Decathlon fuselage while the engine is off for overhaul. Looking for suggestions on how to maintain the finish and appearance of the galvanized firewall.

View attachment 107771 View attachment 107772

Firewall has been removed from the aircraft and is bare, which opens up some possibilities, including:

1. Regalvanize - hot dip
2. Electroplate
3. Powdercoat
4. Paint
5.. Clean and leave alone
6. Replace with stainless

Thoughts?

I pick #5...

 

[Checkout_my_Six]

Zinc it and paint....both sides. Did that to mine.

 

[Bell206]

5.. Clean and leave alone

This.

 

[somorris]

I used #5 on ours.

 

[Checkout_my_Six]

The issue with cleaning and leaving it....is the corrosion will return in a few years.

 

[Dan Thomas]

This.

Yup. It's a galvanized firewall. The zinc will oxidize and it will soon return to the usual blotchy gray. Any sort of paint is a fire risk, and getting paint to stick to galvanized surfaces requires special primers, or it will just peel off and get really ugly. Peeling paint adds to the fire risk.

If there's an aftermarket stainless firewall, that would be the way to go, but what is the point?

 

[Dan Thomas]

The issue with cleaning and leaving it....is the corrosion will return in a few years.

The zinc is there to corrode and electrolytically preserve the steel. The zinc is a sacrificial coating. It's supposed to corrode.

https://gaa.com.au/how-galvanizing-protects-steel/

 

[NordicDave]

Option 5, clean it and leave it.

Painted fire walls look very pretty when they’re installed, but they are a bear to maintain that appearance and look gritty fairly quickly with use.

 

[Jackk]

Go all in

 

[455 Bravo Uniform]

Control yourself

Clean it and keep moving.

 

[Jdm]

I like a polished metal firewall myself.
What about the legality of the other options? Anything goes? Painting is popular with Bonanza boys. The maintenance manual though specifically says not to paint the firewall.

 

[Daleandee]

My experimental has a stainless steel firewall and it looks really good when I clean it during the yearly inspection.

Looking at yours up close it appears to be in great shape. I agree with those that say wash & wax it and go fly.

 

[Ed Haywood]

The factory uses stainless on new Decathlons, so it is readily available, but pricey at $1500. Upgrading would also require updating the fuel shutoff valve and gascolator for another $1K, plus refitting the cowl. More cost and effort than I want.

It looks like the zinc has abraded in some areas around the edges. The firewall is 44 years old and may stay in place another 20 years. I was intrigued by options to regalvanize, such as hot dip or electroplate. Not so much for cosmetic purposes, but more to enhance durability and lifespan.

Sounds like paint and powdercoat are a No Go.