[JesseK]

If you have a linear-slide based elevator that uses ABS as its low-friction sliders, powder-coating is TOTALLY WORTH IT. There was a very noticable difference in lift motor load between our practice and production robot this year because of it.

Other than that -- sure it's a p.i.t.a. sometimes, but in the end it's worth it. You have a product for the whole year, not just a product for the competition season. Also, if you're worried about redoing welds (well, that you have to worry about it is a separate issue) -- duct tape adheres to powder coat better than raw aluminum (FWIW).