Advice please on repairing cast Aluminium parts

Its a fair point, but it may spoil the look of it a bit! If it was to make its way in the distant future to an airworthy project then it probally have a X Ray and other checks so I’m sure it would show up , for display if it looks good then most people would accept that I guess.

These parts are for display only and are not going to an airworthy project.

If so and you “repair” them as mentioned, can you please engrave “scrap” on it ! Although you mention for display only, scare parts have the tendency to be re-used long after anybody remembers how you “repaired” this casting………………

I can second the metal filled epoxy. I used to use it to fill blow holes on water pump castings before they were machined. After the machining some of the filled holes were hard to find.

Devcon metal filled epoxy is good stuff too, for filling holes, divots, etc. Can be filed and drilled. Sticks like excrement to a blanket as well. 🙂

Thanks for the advice :eagerness:

Hi all.

I would use this stuff. Its used to hold Kit Aircraft wings together. I have used it on many many non structural items. Its even been used to glue the handle back on to my best Workshop Coffee Mug !!

Its brilliant stuff.

Loctite® Hysol® 9461 A&B

Description

Loctite® Hysol® 9461 A&B

Loctite® Hysol® 9461 A&B is a toughened, 2K-Epoxy adhesive, suitable for applications requiring gap filling and high peel strength. Ideal for bonding dissimilar substrates like GRP, SMC and composites.

This product requires: Loctite® Dual Cartridge Dispenser

Specifications
• Non-sag paste
• Heat accelerated (4 min. @ 120°C)
• High peel strength

Typical Properties
• Mix ratio by volume: 1:1
• Mix ratio by weight: 100:100
• Working life: 40 min.
• Fixture time: 240 min.
• Colour: Grey
• Viscosity: 270 Pa.s
• Shear strength (GBMS): 24 N/mm²
• Peel strength (GBMS): 10.0 N/mm
• Operating temperature: up to 100°C

PAINTING

For painting Aluminium, you will need an etch primer. something like UPOL #8 comes in a Rattle Can or as a Premixed 1 ltr for spraying. Again, brilliant stuff used widely on kit aircraft small components.

Regards
Mark G-POZA, G-MYII, G-MWWS

Yup superglue or aradite or structural adhesive, if it needs some strength and there is room drill both bits and dowel them with ally rod, bonded that too, most important is degrease it all first..

I’ve used two-part epoxy, like Araldite, but it needs to be heated above any ambient temperature, or it’s likely to soften in (for example) direct sunlight. For holes, heat in an oven, at low heat (100C is plenty,) then apply the epoxy, which will turn liquid and fill the hole(s.) If you need to have it standing proud, you’ll need to fashion a wall, of some kind (I used Blutak.) Put the item back in the oven, for about 30 minutes, remove, and allow to cool, which will allow you to sand down the epoxy, as necessary.
I’ve used the same method to assemble cast metal parts in models; the epoxy runs like water into the joints, so only tiny amounts are needed, and virtually disappear.

If you are only assembling the parts for display and the components won’t be under too much load, also the pieces fit together snugly then why not consider superglue?

Amazingly strong, virtually no bond thickness, and cheap.

Anon.