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How to Use Epoxy for Aluminum Repair

by C.L. Rease

Creating a permanent repair on damaged aluminum generally requires welding. Welding aluminum is a task best left to the professionals. If you do know how to weld aluminum, the equipment is expensive to rent and not cost-effective for small repairs. Repairing aluminum with epoxy is cost-effective and easy. You need to use an epoxy that is aluminum-based to ensure that it bonds correctly to the surface of the aluminum.


Wipe down the surface of the aluminum to ensure that it is dry and then spray the surface of the aluminum with the degreasing cleaning solution.


Wipe the degreasing agent from the surface of the damaged aluminum with a clean rag. Inspect the surface of the aluminum to ensure that it is clean. Repeat steps one and two if you notice that the aluminum is not clean.


Scuff the surface of the aluminum with the 60-grit sandpaper to create a good bonding surface for the aluminum epoxy.


Wipe down the scuffed area with a clean rag to remove metal shavings from the surface.


Thoroughly mix the aluminum epoxy. You need to ensure that the aluminum particles are fully embedded within the epoxy resin. If you are using an aluminum epoxy stick, mix as instructed by the epoxy packaging.


Apply the mixed epoxy to the scuffed surface of the aluminum. Make sure that the aluminum epoxy covers an area twice as large as the damaged area of the aluminum.


Allow the aluminum epoxy to cure as recommended by the manufacturer.


Sand down the epoxy with 60-grit sandpaper to blend the repair into the surface of the aluminum.

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