I'm building a safari rack for my Explorer soon using mild steel ( so I can weld it with my wire rig) square tube and angle. I'd love to have it powder coated, but there are a bunch of add-ons and fittings I plan to make down the road, so I don't want to pay for recoating everytime I grind down part of it and weld on some new tabs or something. What's the most durable, rust-proofing type paint I can put on it in a satin black that I can then touch up as parts get added?
Rustoleum with a brush.
I treat that stuff like Frank's hot sauce.
I always use rustoleum on the interiors of the race cars and the roll cages for just that reason. It fills in the pockets left in the welds and it grinds off easy with a wire brush in a drill. Top coats without any issues anytime you want with a throw away paint brush.
POR or Chassis Saver are both tough as nails and look like powder coat.
TIP: When you go to close up the can, take the nozzle of the TIG and dump some CO2 into the can. It will displace the air and keep the paint from skinning over. Easier with a TIG.
Wear gloves.
POR is awesome. If you're using new metal, pay proper attention to the surface prep.
I put a plastic bag over the top of the can, held in place by the lid. Keeps the lid from getting glued down by the POR.
Hammerite's another one, similar to Rustoleum.
Rustoleum Appliance Paint has got to be some of the toughest paint I've ever used. Only comes in gloss black, white and tan, though.
DaveEstey wrote:
Rustoleum with a brush.
I treat that stuff like Frank's hot sauce.
Noob question, but why is a brush better than a spray can?
thicker application, more solids in the paint and better solvent structure b/c it complies with different VOC regulations when sold.
Thank you, I am now edumacated. 
DaveEstey wrote:
Rustoleum with a brush.
I treat that stuff like Frank's hot sauce.
You put Rustoleum on eggs?
Dr. Hess wrote:
Rustoleum Appliance Paint has got to be some of the toughest paint I've ever used. Only comes in gloss black, white and tan, though.
I used it to paint a hood. Problem is, it flaked off in some spots.
Ever try to sand the stuff? It wears the sandpaper and just annoys the paint.