Stripping Powder Coat

We had a decent sized order for copper bus bars.
They are silver plated, then partially powder coated.

The powder coating needs to be masked, for various holes and slots.

The whole job was rejected at the customer, for some flecks of powder coating into the holes, and around where the screw heads are located.

Is there any way to strip the powder coating, and not destroy the copper or the silver plating?

Thermal stripping seems like a major bad idea, the copper needs to be full hard.
Heat will soften the copper.

Chemical stripping could take some serious time.. And then, will the silver be OK, or need to be stripped and re plated?

My next option is to buy more copper, send it out for water jetting, get it in house, and machine it, send it out for silver plaitng, and try once again, sending it out for powder coating..

Any other ideas or information on stripping just the powder coat..?

Did I mention that the customer has zero tolerance?


The whole job cost as much as the shop truck.. Doing it twice is a killer.

Then, while driving back from the customer a deer jumped out and smashed the shop truck....
It was moment of SHEAR terror, it was withing an inch of coming through the windshield.