The problem with bonding anything to aluminum is that it 'corrodes' practically immediately when in contact with air. This tiny corrosion layer actually helps protect the internal aluminum (I'm NOT talking about anodizing) but it doesn't bond with anything well. SOoooo...if you can abrade the surface while keeping it from coming in contact with air (i.e. using epoxy?) then you might have something. I've never heard of using epoxy between the sandpaper and the aluminum before the idea certainly has merit. The sanding 'dust' might be considered a problem in the epoxy - but as long as it's minimal it shouldn't be much of a problem. Besides, if you add aluminum powder to epoxy, it helps it resist abrasion.


Jake Kohl