Abstract: A process for applying a dual-layer protective coating to steel suspension components of an automobile involves the steps of applying a first coat of the zinc-rich, epoxy-based coating powder to the components utilizing the conventional electrostatic application process; partially curing the layer of zinc-rich coating that has been applied to the steel components such that the zinc-rich coating is gelled; immersing the components with the first layer of gelled zinc-rich coating in a pre-heated/heated fluidized bed of thermoplastic powder so that a relative uniform layer of the thermoplastic coating powder is applied over the first coat of gelled zinc-rich coating; and finally curing the outer layer of thermoplastic powder coating and the inner layer of the zinc-rich coating.