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The key to bonding aluminum
is getting the surface really clean and free of aluminum oxide. Pure
aluminum oxidizes very paidly when exposed to air, leaving a thin protective
layer, but one that is unfortunately not strong. Whatever you do, it will
probably help to make the time between abrading (sanding), cleaning, and bonding
as short as possible. Also, Hysol have epoxies they specifically recommend
for bonding glass or carbon to aluminum. One of these is 9309.3NA. I
bought a quart a few years ago and it seems to me it cost about $138.00 plus
shipping and hazmat charges!
When I had Charlie Kohler
check out and test fly my first ES, he insisted on doing a barrel roll each
way. It was an ... interesting . . . sensation. I haven't tried it
myself with either of the ES's I built.
For you Legacy builders out
there: What are you doing about an external lock? The door handle
assembly doesn't include one.
Jim Cameron
Legacy in Progress
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