Re: how can I apply a washcoat to a nickel monolith?

Some possible assistance.

As I understand it, you want to apply alumina (Al2O3) to a
porous nickel mesh (monolith) to form a catalytic converter.  If my
understanding is correct, you need to find an organization with
Al2O3 (alumina) deposition capability.  If you are a college student,
as indicated, you should be able to find this on your campus if 
microelectronics, or the physics or chemistry of surfaces, are studied 
there.  I think what is needed is capability of depositing alumina in a 
vacuum deposition system.

Otherwise, you should contact a university physics, chemistry, or
microelectronics department to find out where they can get help for this
vacuum deposition project.  Departments where the properties of thin vacuum
deposited inorganic films are studied might have this capability.

Companies that manufacture thin film magnetic heads and some thin film
microelectronics products or integrated circuits might have this capability.
However, it is a 'long shot' that they would help out.  This is because
their vacuum deposition systems need to maintain a high degree of
cleanliness and be free of materials that would contaminate their processes.
The questioners material is of uncertain origin and may not be compatible
with the cleaning processes or material preparation the manufacturer uses.
So, a manufacturing facility might put their process at risk by processing
the questioners material.  They might also adversely affect the catalytic
properties of your material.