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Old 03-12-2004, 10:40 AM
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Bonding dissimilar metals

I am going to do the dreaded cowl repair on my 66 Mustang. When one of my good friends Dad saw the replacement pieces I was ordering, he said he could fab me up a much higher quality aluminum piece. I was considering using Fusor to bond in the repair. Does anyone know if the expansion rates will cause cracking, similar to glass on steel. I am not worried about dissimilar metal electrolysis because my friends Dad will coat the replacement parts first.
Thanks,
Fred

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Old 03-13-2004, 03:20 PM
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Cowl repair

If you are talking about the round vent openings under the cowl, in front of the dash, the plastic ones on the market work fine. They come with silicone addhisive to creata a gasket. I have used them on many resto projects. Know one sees them, and they can not rust. If some one went through the bother to create some out of aluminum for you, that is great. I would any silicone style sealer, and bolt them in.
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Old 03-14-2004, 11:07 AM
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i just did the same repair.
if you work from under the dash the job takes about 6 hours.
removing parts for access takes the longest.
i put in both vent sides with duramix and a couple of screws to hold until the duramix set, then removed the screws.
duramix will bond dissimilar metals.
duramix is much better than fusor, no smell, no slimly coating when dry, and smaller tips for applying
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Old 03-14-2004, 06:33 PM
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Thanks for info on the Duramix, unfortunately my vents are way past a simple hat repair. The pieces being fabbed will be longer than the ones sold in the catalogs, made from .0040 aluminum and coated to prevent corrosion. The large size of the repair was the reason I was concerned with potential expansion rate problems.
Thanks,
Fred
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