Machinable aluminum epoxy?

[C9]

Probably wishful thinking, but I knocked out a somewhat complex round aluminum piece and cut a 1/4" wide by 1/4" deep internal groove in it.

Due to a small miscalculation on my part I need the groove moved outward about .060 - .090 or so.
It's obvious I can't just knock out a ring and insert it cuz it's an internal groove so a couple of ideas are running around in my alleged mind.

Best way, machine a ledge from the outside in, machine a ring for a press fit, press it in, trim to size, cut the new groove.
Machining large diameter rings that are small in cross-section (1/4" square) bring their own problems to the mix so I'm not too wild about that either.

EZ way out if it was possible, fill the groove with a machinable epoxy and re-machine the groove.
My fear is the snap ring and other piece will eat the epoxied area up in no time and create a problem.

The very best way is to machine a whole new piece, but that entails a 40 miles one-way trip to the aluminum store and 2-3 hours of machine work.

Impaled on the horns of a dilemma I am.... http://www.jalopyjournal.com/ubbthreads/images/graemlins/tongue.gif

[Unkl Ian]

Devcon makes a wide variety of specialty Epoxy puttys.
I'm sure they would have something,if color match isn't a big deal.

[a/fxcomet]

Couldnt you weld it up and then start over?

[C9]

Unkl Ian - it's internal so no probs with a color match.
I take it the Devcon is machinable?
And it would stand up to a centralized pressure from a spring loaded device at least as well as the base aluminum?
(6061 T6 fwiw.)

A/FX Comet, that's a viable alernative and I have a TIG, but this is not the time for me to be learning how to weld aluminum.
And also something I hadn't thought about.

Thanks guys. http://www.jalopyjournal.com/ubbthreads/images/graemlins/cool.gif

[burger]

Couldn't you just step up to a retaining ring with a .090 larger OD? If you're using a standard retaining ring maybe try a heavy duty one? I'll hunt through my Waldes book in the morning if this would work for you.


Ed

[Unkl Ian]

Devcon.com (http://www.devcon.com/devconcatsolution.cfm?catid=15)
Their Aluminum putty is supposed to be machinable,I didn't look at any of the others.

[HotRodDrummer]

C9,
Before I actually welded alum. with a tig I thought it would just be too hard.... I was wrong.

and while I am still learning, my puddle seems to flash away every now and again, my dad say's it's to hot...that's something I am working on.

work on it with some scrap if avalible...

I'm sure you can do it just fine.

HRD

[FEDER]

C9 The best stuff Tve seen is Belzona. They make a 2 part compound that is incrediby hard yet easily machinable. I have seen shafts cut undersized and saved with this stuff. BIG shafts like 30' long and 10" dia. They build up the bearing surface and remachine alls well. I used Belzona 2121 to reshape the inside of the intake manifolds for my Hilborn injectors. Im sure they have a website. They make several different types for different applications. http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gifIts no one size fits all product. If you drill a hole in the wrong spot you can fill it redrill and tap it.Its really the top of the line stuff. FEDER

[Unkl Ian]

http://www.belzona.com/

[FEDER]

C9 I found there website I dont know how to post it but just keyword it you will get it. ---FEDER

[FEDER]

Thanks UNK

[rogue]

Cost of the material, Id'e do the 40- 3. Seems cheaper and right.....................

[Bugman]

How does the Devcon handle heat?

-Jeff

[topdeadcenter]

Bugman~

I love your avatar! http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif Tell me that isn't our famous MEL? http://www.jalopyjournal.com/ubbthreads/images/graemlins/shocked.gif

Mike

[C9]

Many thanks.

Went by a friends machine shop to see where I might find some Devcon locally.
Ended up with a chunk of aluminum big enough to redo the whole thing.
With a touch more care this time around.
Actually, I was being careful, just did some incorrect figuring.

Kind of the old story, make one, learn from your mistakes.
Make two and that one will do the job.
Make three and you're an expert . . . I hope.... http://www.jalopyjournal.com/ubbthreads/images/graemlins/tongue.gif

[Flat Ernie]

There's also some stuff called "certainium" or "sertanium" or something similar - not sure of the spelling. I don't know who makes it, but my old machine shop used to use it for repairing cases on outboard engines. It was fully machinable.

Anyone ever heard of this stuff? Is it a devcon product? Or that other company maybe?

http://www.jalopyjournal.com/ubbthreads/images/graemlins/cool.gif