Abstract: In an angular gas cap on a wire thermal spray gun, a forward channel extends from a rearward channel at an oblique angle thereto so as to have a lateral directional component. The rearward channel at the nozzle has a channel axis parallel to the central axis of the nozzle and is offset from the central axis in a direction opposite the lateral directional component. Immediately upon termination of spraying the wire is retracted into the nozzle. A wire positioner includes a hollow collet with the wire extending therethrough. A linear actuator retains the collet against a wall to hold the collet open from the wire during spraying. Upon termination of spraying the actuator retracts to release the collet from the wall so the collet is sprung to engage the wire during the retraction. Upon startup the wire is advanced into the gas cap faster than normal spraying speed.