How thick is too thick?
Things tend to be reasonably standard on karts.
If your powder coaters aren't used to doing kart chassis, they may have put a really thick coat on it and it could be very thick in places like the bearing hangers because they have to get the powder into the bottom of the hanger but the spray pattern is wide so it will be building up more at the top.
Is it possible you can post some pictures somewhere if the problem isn't the thick coating?
If they haven't done many kart chassis you will also have a problem with the bearing at the bottom of the steering column and the stub axle yokes.
You'll probably have to cut the coating out of the bolt holes on the seat mountings too.
What does the chassis plate say regarding the type/model etc?
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