I just bought some durafix rods from the local distributor here in Aus, did some testing on the weekend.
Important point about this stuff was to follow the instructions carefully. few major points:
1. Al oxidises very quickly so it is important to clean well and
2. immediately thoughoughly brush with a stainless steel wire brush (supplied in the kit I bought.
3. need lots of heat, I used a cheap propane torch...it worked but only on smaller pieces.
4. you need to kinda rub the rod into the area to be joined.
first I tried to butt weld two pieced of gen purpose 10mm angle Al. properly cleaned and brushed....failed cause I had it in the vice and there was enough heat sinkin in the vice for it not to get hot enough.
a 70mmx70mmx3mm plate with a 30mm x 20mm offcut rod of 7075-t6 grade alloy: this i did with no real heat sinking and followed the instructions, I also beveled the rod offcut where I sat it end-on in the middle of the plate. proceded to heat and solder...
Viola! nicely joined and so I put it in the vice and proceeded to try to rip it apart. part of the weld broke away as I started (the 7075 was the bit in the vice) then the al plate basically got a hole torn in it and left about a half circle of the plate still attached to the 7075!!! I'd call that a success!!
now had I clamped the pieces I could have "rubbed" the rod properly as instucted without moving the rod offcut around. it was just sitting there on the bench.
tried to do the same as above with some brass rod (this is supposed to be possible) It seemed to flow well onto the brass but the brass was very polished and although it appeared to bond very well leaving a deposit just like it had been "tinned" like when soldering, the bond was VERY poor and required very little effort to break away from the weld....it left all of the weld on the sheet....FAIL but I would like to test this a bit more.
Anyway, I am very excited about making some things with this stuff and am confident that effective repairs and fabrication can be done as long is proper testing is performed and you don't try to weld up a handlebar or anything super critical.
The other thought was that with a hot camping stove and one or two rods you'd be able to field weld cracked engine casings or maybe even a frame if your life depended on it. as longs as you could get the heat into it....some camping stoves have quite a bit of heat output.....maybe ad in a 40 degree day in the desert and you might just have a solution for a snapped suspension linkage (if you ride really slowly!)