404 High-Density Adhesive Filler is an epoxy thickening additive. We developed it for maximum physical adhesive properties in hardware bonding, or anywhere that high-cyclic loads are anticipated. Blended with epoxy, it makes an excellent gap filler or structural fillets. Use 404 High-Density wherever you need an especially strong bond. You can blend it into any WEST SYSTEM 105 Resin/20X Hardener combination, G/flex Epoxy 650, or G/5 Five-Minute Adhesive. Blended with epoxy, it will cure to an off-white color.
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We recommend 404 High-Density filler as the most cost-effective and easiest-to-use filler for hardware/stud bonding. Even small amounts of High-Density adhesive filler help reduce creep in the epoxy. Most importantly, we recommend creating a moderately loose slurry. The mixture should be thick enough to stay in a horizontal hole, but not too thick. Blending too much 404 High-Density filler into epoxy can trap air.
Adding chopped glass fiber or carbon fiber to the mix can increase the load carrying capability. But the additional cost and application difficulty are usually not worth taking this step.
We typically use 800 psi as the ultimate shear stress when testing the filled epoxy mix. This is a conservative value based on long-term fatigue data. At this stress level, the epoxy is the limiting component. The interface between the fastener threads and the epoxy is where a fatigue failure typically starts. This is good. The fatigue failure mechanism for epoxy — cracking and gradual destruction of the matrix — gives some warning. A failure at the wood/epoxy interface or the loss of a bolt head is usually catastrophic. Proper use of this product helps prevent that from happening.
Read more about bonding hardware with High-Density filler at Epoxyworks.com