Hot dip galvanizing

[Vonmagnuson]

I have a fairly complex and fairly large part(about 4'x4'and 4" thick made of formed and welded mild steel parts) to galvanize with many holes that are drilled and tapped and some that are thru. My question is, how do I plug the tapped holes and high precision holes so when the part is galvanized, I do not have to re-drill/re-tap? This could be a fairly high volume part. Every galvanizer we have tried has managed to mess them up.

 

[PVRV]

Please elborate on the following:


1. Is the part in question structual or encasement?

2. Why is not feasible to change the order of works
galvanize and then drill/tap ? Location/transport?

3. Why are other forms of external protection not
considered? (Epoxies, Urthanes, Acrylics, etc)

4. Amongest the attempts that "messed things up" was
the part holes bolted with adquate washers prior
to galvanizing.

Cheers