I built a custom home which was finished in 2012. One of the main features is a “floating” master bedroom which also creates a covered entry way to the house. The front gate acts both as the front door as well as a security gate for the house.

In less than a year, the finish of the front gate has begun to rust looks awful. The gate is made with McNichols plain steel and then powdercoated. Unfortunately the powder coating has failed. I have been working with the powder coaters, my architect and my builder. No one has a good solution to salvage the existing gate. The powder coater will not guarantee the finish and said the finish will likely fail again. The fabricator of the fence, after much discussion willingly took a sample of the same McNichols material and tried to spray galvanize it and then powder coat it but that did not “take”. The powder coater recommended a plastic dipping which is a thermoplastic powder coating. Unfortunately he does not apply this finish. Everyone agrees that a new gate fabricated in stainless steel would be the best solution. I priced this out and it would cost me anywhere from $6,000 - $8000 for material and labor.

Other things to consider: The fabricator will pay to strip the existing rust/powder coat off the fence. Also, the powder coater will re-powdercoat the fence one time at no additional cost. That said, they advised the same thing will likely happen again and I will be in the same situation 6-8 months from now with this option.

As a homeowner and not a professional architect or builder, I am reaching out to the Houzz community for suggestions to leverage my existing gate or the best long term solution.