Restoration vs. Replacement: The Economics of Powder Coating

Don’t Toss It, Coat It We live in a disposable society. When a patio table gets rusty or a car rim gets scuffed, the instinct is often to browse online for a replacement. But with the rising costs of raw materials and shipping in 2025, buying new is becoming increasingly expensive.

There is a smarter, more sustainable, and often cheaper alternative: Restoration. By utilizing the services at Rusty Lions, you can transform your tired, rusted metal items into better-than-new condition. This article explores the economics of restoration and how the powder coating cost compares to the price of replacement.

Case Study 1: High-End Patio Furniture Quality outdoor furniture is expensive. A cast aluminum or wrought iron dining set can easily cost $2,000 to $5,000 brand new. Over time, the factory paint will peel, and rust will set in.

• Replacement Cost: $3,000 for a new high-quality set.
• Restoration Cost: Sandblasting and powder coating that same set might cost $800 to $1,200 depending on the piece count.
• The Verdict: You save nearly $2,000, and you get to choose a custom color that matches your new deck or siding—something you can’t do at a big-box store. Plus, the industrial powder coat applied by Rusty Lions is likely thicker and more durable than the original factory finish.

Case Study 2: Vintage Gates and Railings Many older homes in New Jersey feature original ironwork. These pieces are often heavier and more intricate than modern steel reproductions.

• Replacement Cost: To commission a new custom iron gate of the same weight and detail could cost upwards of $5,000. Replacing it with a cheap, hollow aluminum tube gate might cost $1,500 but ruins the aesthetic of the home.
• Restoration Cost: Removing the gate, sandblasting it down to white metal, and powder coating it might cost $600 to $1,000.
• The Verdict: Restoration preserves the historical integrity of your home for a fraction of the cost of a custom replacement.

Case Study 3: Automotive Rims OEM (Original Equipment Manufacturer) rims are expensive. If you curb a rim or the clear coat starts peeling, buying a single replacement rim from the dealer can cost $400 to $800.

• Replacement Cost: $2,000+ for a new set of factory rims.
• Restoration Cost: Powder coating all four rims at Rusty Lions typically costs between $400 and $700 total.
• The Verdict: For the price of one new rim, you can restore all four to perfection. You also gain the ability to customize the look with satin black, gunmetal grey, or bronze finishes.

The Rusty Lions Restoration Process Restoration is about more than just painting. It’s about resetting the clock.

1. Sandblasting: We strip away years of corrosion. This reveals the raw steel or aluminum beneath.
2. Repair: Once stripped, we can often identify cracks or deep pitting that need attention (which we can address with our metal resurfacing services).
3. Coating: We apply a zinc-rich primer (for steel parts) followed by a durable topcoat. This dual-layer system offers protection that far exceeds the original manufacturing standards.

Conclusion Before you throw away that rusted bench or order new car parts, consider the powder coating cost. In almost every scenario involving high-quality metal, restoration is the financially superior choice. It saves you money, saves metal from the scrapyard, and gives you a custom finish that is uniquely yours. Visit Rusty Lions online or in-person to start your restoration journey today.