I assisted in powder coating one of my race car chassis'.
How thick to apply it depends on how thick you want the finish. There are some items that can be coated up to 20 mils!!!
if you have an intricate piece the details are less apparent and corners and such are softened.
Usually they measure the thickness in Mil's
Less than 1 mil and you will likely have pin holes in your finish.
You can go fairly thick with the stuff its just harder to get a uniform finish.
2-3 mils is what is recommend.
Its tough to figure out the thickness of a Mil, but if you go to home depot and look at masking plastic, look for 3 mil plastic and just try to gauge it off of that. It is not really all that thick.
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