Semi-automatic handguns characterised by the classic Colt 1911 model rely on a reciprocating slide mechanism for loading and ejecting. The moving surfaces require a tight fit to maintain firing accuracy while having ease of movement to avoid misloading or jamming. The electrophoretic painting method is ideal for coating complex geometries where engineering tolerances need to be maintained. The anodically depositable paint system developed for this application incorporates nanosilica for reinforcement of the resin binder and a blend of polytetrafluoroethylene, boron nitride and molybdenum disulphide to provide a self-lubricating anti-corrosive coating. Colourants have been added to provide various appearance attributes. The formulating procedures for producing this type of complex electrophoretic paint are described. This includes considerations of manufacture, shelf life, shipping, application by the customer, and compliance with health and environmental regulations as well as meeting the extreme performance requirements of the end use.