Here are a few simple things you should know about powder coat:
1) New age Powder technology is not like that of that from the stone ages. The newer powder goes on thin as paint. No more thick plastic looking coating. Its available in flats, metallics, candy etc.
2) Like paint, if you can feel it, you will see it. Any imperfections will show.
3) Powdercoating is applied via an electrostatic charge that does not stick or adhere to painted surfaces or any other that isnt bare clean metal.
4) Its baked at +/-500 degrees so keep in mind that some thinner metals may not hold shape during the baking process.
Using bondo is a BIG no no. For starters the powder wont stick to it and second it wont last in the 500 degree oven. You can weld your holes etc up and use a brass welding rod to work the areas of imperfection.
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