Posted for Newlan2dl@aol.com:

The problems with bonding aluminum aren't normally the fault of the aluminum but most often the problem with prepping the material.  Proper prepping should include washing all contaminates off with soap and water, acetone then scrub with a scotchbrite before Chromic Acid Anodizing (CAA) or Phosporic Acid Anodizing (PAA).  Then keep them clean.  For non-structural bonds, I have wetsanded the parts (after cleaning and abrading)  in epoxy to remove the oxide that covers the surface.  This works OK but isn't to be trusted for really critical applications.  Check with Hysol, they have some really awesome epoxies for bonding aluminum but DO NOT use the Jeffco for it!

Dan Newland