Remember this old thread about repairing a chewed but otherwise good cage? We discussed touch-up paint, new cages, related stuff. I finally devised a solution of putting stainless steel washers over the spots where the powder coat had been compromised. It's working out great. Here's a sample of a formerly-chewed corner. The bird keeps a cage he knows; I save money; bird is safe! Win-win-win!
When he chews a new spot... I have washers at the ready.