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Re: Powder Coating
The end result of Powder coating is very much like paint, and while it adds thickness, it can always be chipped off. I would recommend breaking your robot down into the farthest assembly you feel you might disassemble to. (ie. just your robot frame). As for holes, you can always ream out a hole with a drill bit after it has been coated, and if thickness is a problem a bit of sanding will fix the problem. I would not powder coat over hex screws unless you think you will never take them out. Remember you can always mask off areas you don't want finished.
The thickness of powder coating depends on a bunch of variables such as partial size, color, etc. typically the range in thickness is between .003 and .005"
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