Step 1: Prepare and Clean the Door Panel

Start by removing any handles, locks, or hardware that might obstruct your painting. Thoroughly clean the armoured door panel using a degreaser or a mild detergent to eliminate dust, oil, and contaminants that could hinder adhesion. Wipe dry with clean, lint-free cloths.

Gently sand the metal surface with 220–320 grit sandpaper to create a key for the primer. Pay special attention to corners, edges, and any rust spots—sanding them until smooth. Remove sanding dust with a damp cloth and mask off any areas not to be painted to prevent accidental coating.

Step 3: Apply the Epoxy or Polyurethane Topcoat

Once the primer has cured, select your preferred finish—epoxy or polyurethane. For armoured door panels exposed to weather and heavy use, a two-component polyurethane such as “Prolux” – PU coating for tiles, concrete, plastic and metal – suitable for driveable surfaces provides outstanding durability.

Mix the components according to the manufacturer’s ratio (for Prolux, 2:1 by weight). Apply with a high-quality brush, roller, or spray equipment in thin, even coats. Avoid overworking the product, as this can leave streaks or bubbles. Let the first coat dry fully before applying a second layer if needed for complete coverage and maximum protection.

Tips, Common Mistakes, and Troubleshooting

• Always work in a well-ventilated area with appropriate PPE. Epoxy and polyurethane products release fumes—use gloves, goggles, and a mask.
• A flawless finish is achieved through thorough surface preparation. Skipping cleaning or sanding can lead to poor adhesion and peeling.
• Allow each layer to cure fully before applying the next. Rushing this step risks trapping solvents and causing bubbles or cloudiness.
• Don’t apply thick coats, as this increases the chance of runs or uneven drying.
• If in doubt, test the coating system on a small, inconspicuous area first to check compatibility and finish.