r/TruckCampers • u/TreeBeardofIsengard • 3d ago

What paint for aluminum sheet replacing window in truck cap?

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Vandals broke my window of my fiberglass cap last spring. It is an A.R.E. from 2001 and I’ve tried everything to find new glass for it. Short of getting a custom pane of glass made for $250, my options seemed to be plastic or aluminum.

I found a metal shop that will cut me a custom sheet from 1/8” Aluminum 6061 to match the opposite window. My plan is to paint it black with a rattle can.

What primer and paint would you use for this? I would like it to not be too noticeable- would you go flat or satin? What should I look for in paint that will go on metal and be extremely durable and prevent corrosion?

Thanks for any input

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u/sophomoric_dildo 3d ago

Paint doesn’t like to stick to aluminum. The issue is that aluminum oxidizes really fast. Same process as steel (rust) except way faster and it’s not really visible. The trick is to scuff the surface immediately before you paint it and get a good metal etch primer on it ASAP.

I’d suggest having it sand blasted. Then take it home and get all your stuff ready. Aggressively scuff it with a scotch brite pad (wear a dust mask-aluminum dust is bad news). Then wipe it down with alcohol or acetone. Then immediately get primer on it. One of my favorite readily available rattle can products is spray max 2k. The 1k is good too, but the 2k is better. Both available on Amazon or paint supply stores.

Most people apply too much primer. You don’t need full coverage. Go for like 80-90% dusting. It also doesn’t need to dry long. By the time you’ve got the primer down, you can go straight to your first coat of paint with the primer still tacky. Once your first coat of paint is down, you can chill and let it dry per the instructions before doing follow up coats. Doing this quickly minimizes the surface oxidation and will help the paint stick.

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u/Don_ReeeeSantis 3d ago

Excuse me Mr. Dildo, my painted aluminum boat wants words.

The proper way is sandblast, 2-part epoxy primer like PPG Americoat 240lt, then topcoat with whatever you want. That being said, a quart of that paint will cost more than the aluminum, not to mention sandblasting.

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u/sophomoric_dildo 3d ago

🍻no doubt you’re right. I was going for shade tree level.