The paper gives a detailed discussion of the various engineering and safety issues related to the demonstration of an advanced cost reduction strategy at a U.S. Marine Corps maintenance facility in Barstow, CA. Details discussed included hardware solutions to flow control, real-time volatile organic compound (VOC) level detection in the recirculated stream, maintenance intervals of multistage exhaust filters, and hardware and software solutions to other unique process control challenges. EPA desired to show that partitioned recirculation, developed over a number of years and projects, could be designed and built as easily as existing non-recirculation booths by using existing industry practices and a minimum of custom design. At Barstow, partitioned recirculation and other techniques allowed a reduction in VOC control equipment cost by reducing the flow rate from about 142,000 to 43,000 cfm (67 to 20 cu m/sec) while achieving total exhaust treatment.