Important: Heat the job, not the rod. Do not use an ordinary steel brush!
Step 1 – Preparation
Use a stainless steel wire brush thoroughly on and around the break or hole. Alternatively an aluminium oxide grinding disk or a clean brass wire brush may be used. All oxidisation, dirt or foreign substance must be removed.
Step 2 – Heating
Using a torch, heat the area to be repaired. Do not apply torch to the rod, but to the base metal. As the repair area becomes hot, rub the rod vigorously over the heated area, being careful to keep the flame moving ahead of the melting rod. The slick, shiny film of material now appearing indicates that the proper repair temperature has been reached (400C). Let the rod act as a thermostat. Do not overheat, as aluminium melts at approximately 600C.
Step 3 – Repairing
Now, rub the rod more vigorously, with a scrubbing motion around the area to be repaired. Build up an excess of melted rod around the break. Using the rod, draw the molten ROD over the entire area, closing the hole or crack. You should now have a repair stronger than the base metal.