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 this filler 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.
VIDEO: How to Guide for Adding Fillers to Epoxy
We recommend 404 High-Density filler as the most cost-effective and easiest-to-use filler for hardware/stud bonding. Even small amounts of this adhesive filler help reduce creep in the epoxy. Mix this filler into liquid epoxy to create a moderately loose slurry. It should be thick enough to stay in a horizontal hole, but not too thick. Blending too much filler into epoxy can trap air.
To increase the mixture’s load-carrying capacity, you can add chopped glass fiber or carbon fiber. However, 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. We base this conservative value 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 the gradual destruction of the matrix—provides you with some warning.
A hardware bonding failure at the wood/epoxy interface or the loss of a bolt head is usually catastrophic. Proper use of this product helps prevent these things from happening.
Read more about bonding hardware with WEST SYSTEM epoxy at Epoxyworks.com
VIDEO: Journey Everyday offers an excellent demonstration of filling holes with 105 Resin/205 Fast Hardener thickened with 404 High-Density Adhesive Filler.