OK how 'bout this, Is the "plunger/piston" shaft by itself longer than the ID of the main body tube? If not could you assemble the unit from the inside after the e-coating process? You might need to build a special tool to insert and hold the plunger.

So, you ecoat while it is in it's default "extended into jug" position? Then clean the part of the plunger that is exposed?

We actually do that on one of these that gets a different knob. It works well, but there is VERY little room inside the tube. The one in the picture is a large diameter version made from 1" DOM. We also do it in 7/8" DOM which does not allow pin insertion after the fact. We would hate to have two different processes. Plus it would be very difficult to do the press operation with limited space and not mar the finish.

Good idea though.

When the part gets e-coated there must be conductive contact between the part and the rack they hang on. We pull the plunger out and hang them in a "U" shaped detent on a rack. The spring tension holds them to the rack.

This means the plunger is pulled back about half way. We could pull it back even more, but then the pin just under the knob would be even more exposed causing more buildup issues there. But if I catch what your saying it would be easier to clean that since it is exposed, you have a good point! Perhaps it would be easier to protect from paint as well???? No were gettin somewhere.

See we've been doing these for nearly 15 years. It's hard to believe but we've always just dealt with it. In a small shop the tendency is to move on to the next thing as soon as possible. With the holiday slowdown I've been using my time to increase productivity on some existing jobs.

Thanks again guys I have a couple ideas and will let you know how the test goes this week. Thanks again!!!!!!!!!!!!!!

If it's exposed for cleaning perhaps a custom made sock/fitting can go over (or clamped onto) the part to be cleaned....then blast media into/through this cover to clean the part. Kind of like the spark plug cleaners that used to be available.

raise the price and outsource it.

LOL, yea that's just what they did, I'm the "outsourcee":)