In the present study, nanosized silica particles (similar to 100 nm) were incorporated into epoxy polymers, and then sprayed on molybdenum treated Al coupons (2024-T3) by a nozzle spray unit at different thicknesses. A urethane top coating (1 mil) was also applied on some of the initially coated surfaces. The main purpose of the SiO2 and urethane was to absorb/block unwanted ions/molecules (i.e., Cl-, O, OH-, H2O, etc.) and increase the coating performance. Several corrosion tests including electrochemical impedance spectroscopy (EIS), salt spray and salt soaking were conducted on the prepared samples using a 0.5 M NaCl solution. The Al coupons coated with such nanocomposites and a urethane top coating showed excellent coating resistances (8x10(9) Omega-cm(2)) against corrosion attack. As a result, it is assumed that this novel coating system will allow coating industry to effectively protect the surface of materials.