One sneaky trick (I should patent this) when bonding aluminium and it's alloys with a suitable grade of epoxy (as per my previous post) is after cleaning the aluminium surface with phosphoric acid (such as this readily available product here in Oz) **LINK** (or just simmering the aluminium with a bunch of rhubarb leaves works ok), smear the epoxy onto both parts to be joined, warm the epoxy with a hot air gun until it is runny and scratch the hell out of the aluminium substrate below the epoxy with a sharp disposable scriber (piano wire) – don't break the surface and let any air in btw. Then press the parts together for an excellent bond.
This is similar to the method for brazing aluminium with some of the repair kits – One just has to keep the aluminium from oxidising.
* Danny M *