On Thu, 22 Mar 2018 10:13:11 -0700, sms
wrote:

On 3/22/2018 8:48 AM, Jeff Liebermann wrote:

9200 - Dual cartridge 25 mL (0.8 fl oz) 1:1 STRUCTURAL EPOXY ADHESIVE
https://www.ebay.com/itm/MG-Chemicals-9200-Structural-Adhesive-25-mL-Dual-Syringe-/132476402539
$13.50 for 25 mL. However, you do have a point. Considering the tiny
quantity needed for gluing the lever back together, a less expensive
adhesive might be a better choice. Unfortunately, I couldn't find a
cheaper low CTE and low shrinkage epoxy.

Do you really believe that given the tiny surface area and the large
forces applied to brake levers that any adhesive could possibly work?

Yes. The glue joint won't be as strong as the original aluminum
forging, but should hold together as long as you don't crash the
bicycle. If the levers are hollow, a steel reinforcing rod down the
center cavity should provide sufficient strength. If solid, drilling
and adding a steel roll pin should do the same.

The strength is not in the glued butt joint, as you seem to suggest.
It's in the roll pin or center rod. Simply slopping on some glue to
the broken area and butting them together, isn't going to hold.

You would have to reinforce the repair with some sort of splice. Way too
complicated to try to save zero dollars.

Well, if it's too thin for a pin through the center of the lever, then
tacking the pieces together, milling several slots across the broken
area, and pounding in a roll pin, should be sufficiently strong.

--
Jeff Liebermann
150 Felker St #D http://www.LearnByDestroying.com
Santa Cruz CA 95060 http://802.11junk.com
Skype: JeffLiebermann AE6KS 831-336-2558