[ironbears]

Seeing as how I worked at a powdercoating shop last year, I think I may be able to answer a few questions. Each company is unique and some smaller companies may have size restrictions on how big the parts can be, as the material needs to be cured in an oven. In addition, the metal is sandblasted (very fine) so the powder will adhere. Like Greg said, any sections you do not want powdercoated will need to be taped off (Duct tape for the sandblasting, and painters tape for the coating).

Now for the screw question:
You won't be able to fit a standard Allan key into the screw head, you will have to tape off all screw heads. As well if you decide that you want to powdercoat the robot assembled, held together with Allan keys, you will find the powdercoat will chip around the screw hole if you decide to take the screw out. To prevent this you will need to score around the screw head with a sharp knife (safety is important).

Hope this helps.