How to fix corrosion on aluminium door?

RomanL

Hi there smart people of Bunnings,

Any ideas how to fix this balcony door frame please? I assume it is some kind of aluminium corrosion (white/grey powder).
I live near the ocean so that explains it, but is there any chance to fix this so it would last another 2-3 years?
I understand I will need a replacement of a new frame which is 15k+ but would like to postpone this expense if possible.

I am considering to clean it the best as I can then fill it with some sort of epoxy and protect it somehow with some paint, tape.
I know this would be a temporary solution as I am sure this damage goes up further, not yet visible on outside

Appreciate any advice.
cheers,
Roman

from insidepiece fell outfrom outside

EricL

Hello @RomanL

Welcome to the Bunnings Workshop community. It's sensational to have you join us, and thanks for sharing your questions about your aluminium door.

To temporarily support the post in place I suggest installing an angle bracket such as the Carinya 150 x 125 Zinc Plated Angle Bracket. However, I suggest getting a second opinion in regards to the replacement of the aluminium post only. Getting just the post replaced should reduce the repair cost significantly. In this instance, I don't think the post will be lasting much longer as the corrosion is quite severe. The sooner you can have it replaced the better.

If you need further assistance, please let us know.

Eric

RomanL

Thank you for your reply Eric!
That's a great idea to replace the post only, I will look into that as well.
Thanks again

R4addZ

Hi @RomanL

If you decide to go down the path of repairing the post you need to be aware that you can't just use normal fastening systems as, for example, a steel screw or bolt will cause corrosion. You need to use stainless steel components (even in parts that just come into contact with the aluminium such as brackets. There is also a special filler for aluminium and though a quick search of Bunnings web site didn't show it up, I'm sure they can special order it in. An example shown in the link below....

https://www.swiftsupplies.com.au/aluminium-repair-stick

MitchellMc

The closest product we would have to the one @R4addZ has mentioned would be PC Products 57g PC Metal Epoxy Putty. However, given the structural nature of the deterioration, I'd be looking at trying to replace the upright, as there doesn't appear to be much material left in the post.

Mitchell

RomanL

Thanks Mitchell, I will check that out.

I also found https://www.bunnings.com.au/selleys-110g-knead-it-steel-epoxy-steel_p0352313
It says in description it can be used with aluminium..

I agree with you about replacing that post or whole frame though. I might still use this epoxy for time being as even if I do not do anything, it would easily last another 6months+ It will give me some time to find a company that would be able replace just one post..

thanks

RomanL

Thanks mate, that's a great idea for a temporary solution.. all the best!