I have 1000s of hours of spray paint experience, but only 10s of using cans. When I finally start painting and decorating some pedal boxes, I thought I’d do a pictorial of the steps my shop uses for spraying lacquers. But, I also taught at a few schools that had spraybooths, but students needed to use rattle cans—so I got to see many of the potential failure modes for rattle can painting.
Here’s some brief thoughts:
1. Aluminum does not take paint well. After thouroughly cleaning with a good solvent, stick the box on top of an object that will hold it away from any surfaces. You need to have airflow around it, that’s what conveys the paint mist. We use double stick tape, and in this case, just some short sticks.
Use an etch primer. This is the trick to having a secure paint coat. I know these are available in rattle cans, but I don’t quite understand that, as what we used was always a 2 part mixture, that activated as an etchant when mixed together, and then had a shelf life of a few days… In any case, use an etch primer if you can.
2. Try to stick with one brand, and if it’s a big brand, like Rustoleum or Krylon, the same “product family” from that company. If you use paints from different companies, you may experience weird interactions between the coats. These might be never fully curing, or bubbles, or wrinkles, or? And the killer is, it may take a few weeks to happen. So, if you have to mix brands, test everything, give it a chance to cure, and see what’s up.
3. Spray cans spray very thick (by a professional painter’s standards) coats—by the time you fully wet a surface, you’ve got a few times as much paint there as a good spray gun user. This makes the whole curing issue really critical. A major difference between solvent based paints and poly or water based paints is that each coat slightly melts the coat below it. Softens it, due to the thinner in the new coat.
A thick coat will very often skim over across the top, and while the solvent vapors do make their way through, as that skin gets thicker and thicker, the gas release slows down.
If your surface is much warmer or colder than where you’ll be storing it to air it out while curing, you may get issues. We had a drying cabinet for small parts, usually ran it somewhere between 100 and 125 oF. If you’re getting good results with 300 oF in a toaster oven, I’m surprised, but that’s great. Just make sure most of the offgassing has happened; otherwise you‘re sending out highly flammable gas into a small enclosed space with glowing wires…