using bondo on aluminum surface ?

[vacpress]

For a cosmetic finish, I think bondo would work far better than JBweld or other metal-filled epoxies. Bondo sands nice, epoxy usually dosent...

you have to be carefull with bondo.. pressure will crack it if under a joint..

good luck..

[tool_man]

Devcon makes a 2 part epoxy putty that has aluminum dust in the resin.I have used this stuff before and it works very well.Just a thought.

[Tom Brown]

Depending on how deep your defects are, you might do well with a spray type polyester filler/primer. From there, you're ready for a quick sand and paint. Polyester products stick great to Al and aren't expensive.

If you're talking about defects to a maximum of roughly 0.030, I suggest polyester filler/primer (or epoxy filler/primer but it is an order of magnatude more expensive and extremely dangerous to work with)

If you're talking about defects to a maximum of roughly 0.100", you could go with polyester or epoxy glaze compound. I recommend Metal Glaze because it goes on smooth and sands like butter.

If you're talking about defects over 0.100", you might want to consider the drywall compound jacket technique that some of the guys speak well of or otherwise improving your castings a bit. Alternately, you could use a bondo type product.

... just a couple of ideas from a bodyman.