Powder coating adds probably a little more than that.  I design bridge 
consoles for ships and we have to run taps back through all the tapped 
holes and make sure none of the clearance holes are too tight.

I use Tool Black from Precision Brand Products in my machine shop for 
steel parts.  It is a black oxide coating and adds only something like 
.0002 to the material.  You can buy it from www.use-enco.com .  You can 
also use gun blue from your local Wal Mart gun department.  With either 
of these you still need to oil the part.  They make more of a porus 
surface to hold the oil than a coating to prevent corrosion.

I wrote a product review on the Tool Black that was in the March/April 
2001 issue of The Home Shop Machinist that had some instructions. 
 Contact me if you want an emailed copy.

Mark Langford wrote:

>Mark Youkey wrote:
>
>>I looked in "The Science and Engineering of Materials" and found that
>>perhaps the best way is to zinc plate the steel.
>>
>
> Hey, I have that book too!  Guess I should have opened it.
>
>Actually, I'm looking for something I can do at home, but I may have to go
>that way.  I also considered powder painting it, which is supposed to be
>only .002" thick, but last time I had something coated it looked more like a
>.100", and had runs all over it.  They make home-brew kits, so that might be
>an idea.  But plating is a distinct possibility, assuming they can handle
>something 8 feet long.  Waxing may just get me there too, as long as I
>inpect it every time the wings are off, and it'll make it operate with less
>friction.  Call me optimistic on this one...
>
>Mark Langford, Huntsville, AL
>N56ML "at"  hiwaay.net
>see KR2S project at http://home.hiwaay.net/~langford
>
>
>
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