What Can Fill a Crack in Aluminum?

Cleaning

• The aluminum should be degreased before attempting to repair the crack. Degreasers are usually solvent-based and effectively dissolve grease and dirt on aluminum and other surfaces. Leave the degreaser to act on the aluminum according to the instructions on the bottle. Wipe clean after the recommended time has passed.

Preparing the Crack

• The crack should be cleaned with warm water mixed with three or four drops of dish soap. Degreaser may still remain here and may prevent the epoxy adhesive from successfully binding. The crack and the area surrounding it can be cleaned with a soft, dry cloth. Leave the crack to air-dry for another 10 to 15 minutes before applying the epoxy adhesive.

Epoxy Adhesive

• Epoxy adhesives contain harsh chemicals that can aggravate the skin and eyes. Wear a pair of rubber gloves and protective goggles during preparation to avoid any irritation. Epoxy adhesives usually come in two parts, the hardener and the activator. Once mixed together, these substances form a chemical reaction that makes it suitable for binding to materials such as aluminum. Place the hardener and activator in a plastic container as recommended by the instructions on the packet. Stir for around 60 seconds using a stick or spoon.

Application

• Epoxy adhesive can be applied with any flat tool, such as a putty knife. Gather up more epoxy than necessary if you are unsure how much the crack will require, as you can always tidy up areas around the crack as you apply it. The adhesive can be applied directly into the crack. Flattening the knife flush against the surface of the aluminum will help ensure the adhesive penetrates deep into the crack and leaves no air pockets. Curing times vary according to manufacturer, but are typically around 16 to 24 hours.