Need plastic advice

[originator]

I have an aluminum part that I machine that has a thin separation between two parts(.05"), and requires filling the gap with black or gray plastic or epoxy to leave a seamless surface. At first I used a two part epoxy to fill it, and left some excess, then sent the part to the anodizer and he sanded it smooth so that the epoxy was seamless with the two metal plates and very smooth across the separations. That process looks the best, but due to the heat involved in the anodizing and cleaning, the look was inconsistent. It sometimes turns gray or became incositent looking as far as color. I then tried anodizing the part without the fill epoxy in it, and tried to fill it after it was anodized, but the look is not as good as when it was grained at the same time as the part.

I am looking for a solution to get a consistent look on a part I will be making lots of. Since I can't sand the part after it is anodized, that means using a solvent to smooth it out when cured or almost cured, which is not a good look, plus it is very messy and time consuming.

Anybody got any suggestions?