Some time ago, Vern Haller posted results he had in using an aluminum brazing rod he got from Harbor Freight.

Recently I was pointed to a similar product called "Dura-Fix 3in1", see:

This had been written up in Practical Sailor and other boating rags.

I tried it today and am amazed at how easy it works and how strong the joint is (their web site gives some impressive strength stats).

As a test, I butt joined 2 pieces of 3/16" alu (4 " wide)... Then I tried twisting this test piece and could not break the joint... I did another sample and tried bending the piece 1/8" below the joint... The piece bent but the joint held.

I gave a stick to the welder in our yard and, after trying it, he is **extremely** impressed.

The job I had in mind for the product was in making up a mast step for the E27... The original had to be hacked around to get it out of the mast originally (humungous corrosion problem)...

Using 1/4" alu plate as the base, and 3/16" plate (suitably formed to the mast profile) as the vertical flange I brazed the 2 pieces together and now have a super mast step.

I used a propane torch as the heat source and the job took me 5 minutes at most... Wonderfully formed fillet on both sides of the flange, look great. I can thoroughly recommend this product.

BC