Lee wrote:
I have a variety of composite structures that need to be filled.  I have
been using hardware store Bondo for this lately.  It works well enough
except it is way too hard, difficult to sand to a finish without boogering
up the surrounding surfaces. It's also rather heavy.

There are 2 options, same fillers, different resins.
Epoxy is great stuff, but if you have a poly resin to begin with, you can
stick with poly resins, unless
there is a critical adhesion issue.
You will thicken the resins with micro balloons and a bit of fumed silica to
prevent sagging.
You keep the silica to a minimum or it gets harder to sand. You can use a
lot of micro balloons
in the mix if it isn't structural. I have used over 400% by volume to get an
almost dry-ish mix that
can be stuffed into major gaps. You work a bit more resin in to the top
layer to get a smoother finish.
This results in a light filler.
Epoxies are more flexible and adhere better, but once you have epoxy on a
surface you are stuck
with using only epoxy there after.
This isn't as important with small airplanes, but can make a huge $$
difference with large boats!

Mark Mech (Back in the desert after towing a trailer through 3 days of
California storms!)
www.aerofoam.com

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