A single-step dip-coating technique was developed to produce stable films or washcoats of controlled thickness, surface area and pore-size distribution on alumina whisker-covered metal substrates (both flat plates and monoliths). Dip-coating slurries were prepared by dispersing fine porous powder in a colloidal silica sol. The method provided control over coating thickness and coating properties, such as pore-size distribution and surface area. The coating thickness could be varied between approximately 2 and 40 mu m by selecting slurry composition and withdrawal speed in the dipping procedure. The pore-size distribution and surface area could be varied by changing type and amount of porous filler material in the dipping slurry. Uniform and bimodal pore-size distributions were obtained using silica and ZSM-5 molecular sieves, respectively, yielding coatings with surface areas between 60 and 400 m(2) g(-1).