A used component, such as an engine block (30) or engine head (20), has at least one dimension (12, 112) that does not match a dimensional specification for the component. A thermal spray coating (13, 113) of FeAlSiC is applied to build up the dimension (12, 112). The excess coating (13, 113) is milled off so that the body (11, 111) and coating (13, 113) have a second shape that matches the dimensional specification for the component. The coating (13, 113) has an ordered DO3 crystal structure with a stable aluminum oxide scale that produces oxidation resistance at about 700 DEG C.