I bought a used bull bar/push bar/brush guard (they don’t make them
For my truck anymore). Hat to heat and beat out a couple of dents, black some pitted rust spots, applied a little filler and primed with etching primer (rattle can) then filler primer and top coated with Plasticoat Grill and chassis paint (rattle can).

Did the same thing to my tow bar. Put them aside in the garage and worked on other things. Ended up with chips, scratches, and dings in the paint. Obviously not going to withstand much real world use.

What now?

Always been afraid of mixing and spraying paint but sounds like it’s time to get over that. Advice please.

Rod1701 wrote: . . . Always been afraid of mixing and spraying paint but sounds like it’s time to get over that . . .

You answered your own question.
Strip to metal, remove all rust and rust remover. Media blasting is best.
First thing applied should be a quality two part epoxy primer.
Apply filler where needed and seal with epoxy primer.

What goes on next really depends on your plans for the truck.

'68 Coronet R/T wrote:

Rod1701 wrote: . . . Always been afraid of mixing and spraying paint but sounds like it’s time to get over that . . .

You answered your own question.
Strip to metal, remove all rust and rust remover. Media blasting is best.
First thing applied should be a quality two part epoxy primer.
Apply filler where needed and seal with epoxy primer.

What goes on next really depends on your plans for the truck.

I tried blasting but the old finish wasn’t coming off except where it was dented and peeling/cracked. Could it be powder coated? And what would prep be in that case?

Rattle can paint is NOT going to hold up well on most things. If the grill guard is going to see some rough service, maybe put some bedliner, or rubberized undercoat on it?

If you choose to have it powder coated then take it to a place that does that and let them do the prep work. Otherwise you won't have a warranty.

I do want a smooth finish in matte black so not interested in Rhino liner material at this time just a finish that will stick to the bar. Not going to be seriously abused but should be at least as durable as the truck finish.

Just to be clear, I wasn’t suggesting that I powder coat it but wondering if the original finish was a powder coat because I had difficulty blasting it off. If it is, what steps would I take to prep and top coat?

powder coat can be scuffed and painted.

Hard to tell what your dealing with? It could have been Powder coated very tough stuff.
But Epoxy is also Hard to remove even when blasting I have seen some that were almost impossible to remove.

I would Blast it and Paint it with Epoxy though. Then Paint with BC/CC, Epoxy doesn't have any UV protection so it wont hold up to UV rays and will fade in Sun light with Time.

If you want spend the money like Jim said Powder coat is very tough coating.

I would check with a powder coater and get a quote, most have a powerful sand blaster to remove the old powder coat or they can sometimes bake it off. I would guess that buy the time you get materials and equipment and try and do it yourself the powder coat will be less and so much better. around here you can get things powder coated for less than a quality paint will cost you.
Jay D.