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  #11  
Old 01-19-2018, 10:02 AM
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DanH DanH is offline
 
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Quote:
Originally Posted by Bavafa View Post
How about just metal glaze, something like this Evercoat 425 Metal Glaze Ultra
Good example of a polyester-base filler. Should be fine.

Polyesters shrink, so consider epoxy for more than a thin wipe.
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  #12  
Old 01-19-2018, 11:11 AM
lr172 lr172 is offline
 
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I used Evercoat Rage (polyester filler) with good success on my plane. This is a premium filler that adheres and sands better than straight bondo and cheap fillers. 500 hours and no issues. These fillers stick well to aluminum if prep'ed properly (sand, not scuff, and cleaned very well) and I find them easier to work with than epoxy, but I have done a good bit of auto body work so familiar.

Larry
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  #13  
Old 01-19-2018, 11:37 AM
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Av8torTom Av8torTom is offline
 
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Default Thanks Everyone

Thanks Larry - one of my concerns with epoxy is that it would be hard to sand
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  #14  
Old 01-19-2018, 12:15 PM
Aluminum Aluminum is offline
 
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Quote:
Originally Posted by Av8torTom View Post
I'm afraid epoxy and micro would not be flexible enough.
Straight epoxy/micro will be plenty flexible and won't ever come off. For strongest bond, expose bare aluminum shortly before application (minutes) using sandpaper, or chemical etch with phosphoric acid. (Home Depot sells phosphoric acid in glycol for half the price of AS&S; they call it "Prep & Etch".)

Having said that, I made a bit of a mess when epoxy/micro dripped onto uncleaned oxidized aluminum while I was glassing in pieces of canopy. That reminder has been sitting there on thin fuselage skin for about five years unprotected; no signs of it ever coming off despite all my wishing. I also filled in some pop rivets with bondo: none ever fell out, also unprotected.

If you are really paranoid about flexing, thin the epoxy/micro mixture with 5% acetone and spray, that way you'll end up with shorter chains resulting in much weaker, more flexible polymer:

https://epoxyworks.com/index.php/thi...-system-epoxy/

Or simply use J-B Weld, which is a 3-4000 psi mixture with etchant, and nice matching color to boot! Heavier though.

Your biggest problems with epoxy/micro will be: it keeps sagging after application to vertical surfaces (use lots of fast activator, work fast) and, it takes quite some effort to sand because it cures so hard. Cracking and pieces falling off aren't on this list.
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  #15  
Old 01-19-2018, 03:15 PM
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Quote:
Originally Posted by Av8torTom View Post
Thanks Larry - one of my concerns with epoxy is that it would be hard to sand
That's pretty much a function of the filler, not the resin system.
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  #16  
Old 01-19-2018, 04:21 PM
Taltruda Taltruda is offline
 
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Quote:
Originally Posted by Av8torTom View Post
Thanks Larry - one of my concerns with epoxy is that it would be hard to sand
Epoxy with micro sands like drywall plaster! Super easy. Epoxy with flox is hard to sand.
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  #17  
Old 01-20-2018, 02:24 PM
laz laz is offline
 
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If you are concerned about flexibility or adhesion use West system G-flex resin . It was developed to bond to dissimilar surfaces and specifically aluminum. It never gets supper hard and is used in the boating industry to repair aluminum Boats. You can mix micro ballons with it and get a really good filler. the more Micro you use the easier it is to sand. If it gets stiff while applying just run a heat gun over it and you can really smooth it out.

It comes in two flavors, Thickened which is what I mostly use and normal which is about the consistency of normal west epoxy. Just make sure you really prep the area well clean clean clean and rough the area up. I would probably used the thin stuff to make a filler.

When I built my 8 we used to attach the piano hinges on the Cowl. I did a test piece and challenged visitors to tear it apart. Its still in one piece. The really big deal is that it has enough elasticity to withstand temp changes.

I think there is a Youtube video showing a patch made with Gflex being applied under water. pretty amazing .
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  #18  
Old 01-20-2018, 02:40 PM
danny danny is offline
 
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I have some on my motorcycle but I never thought of putting them on my plane(bullet hole stickers)....Awesome!
Just ordered some from amazon.
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