Another Aluminum Repair Method
 

Just stumbled on this Youtube vid and was impressed by the repair of a motorcycle engine cover. Its a long vid so I captured pics of the procedure. Essentially the cover is placed in a box of sand and the hole is cleared. Molten aluminum is then poured into the hole. The aluminum plug is mostly held in place by the inner edge and ragged pattern of the hole. This method might be of use in some bicycle repair needs and is certainly worthy of placing in that useless ship file in the back of our brains...


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Youtube:Man Restores 40-Years-Old Classic Motorcycle Back to New

I'm not sure if any of the kinds of parts and alloys used with bikes would benefit from this method. It wouldn't restore strength to something like a crank or stem, and it probably wouldn't bond. Stuff like housings or boat props aren't as structural or use as refined alloys.

This reminds me of the process for putting cast handles on kitchen knives.

I agree. Kinda reminds me of how dents were repaired with pewter and lead before the use of Bondo. It certainly would not contribute strength, but it could restore a clean look to the surface. It would certainly be more resistant to oil and water then Bondo and most domestic type epoxies.

Here is another repair worth looking at: Youtube "Simple Lead Repair"


youtu.be/3L1HEfQZ-0g?si=zt0P5k1vmlrKtRuK

the only thing it would work on is Shimano cranks