Epoxy repair on aluminum

[C9]

Probably wishful thinking, but I knocked out a somewhat complex round aluminum piece and cut a 1/4" wide by 1/4" deep internal groove in it.

Due to a small  :? miscalculation on my part I need the groove moved outward about .060 - .090 or so.
It's obvious I can't just knock out a ring and insert it cuz it's an internal groove so a couple of ideas are running around in my alleged mind.

Best way, machine a ledge from the outside in, machine a ring for a press fit, press it in, trim to size, cut the new groove.
Machining large diameter rings that are small in cross-section (1/4" square) bring their own problems to the mix so I'm not too wild about that either.

EZ way out if it was possible, fill the groove with a machinable epoxy and re-machine the groove.
My fear is the snap ring and other piece will eat the epoxied area up in no time and create a problem.

The very best way is to machine a whole new piece, but that entails a 40 miles one-way trip to the aluminum store and 2-3 hours of machine work.

And yeah . . . I did tear my hair and say a few bad words.
Thought about kicking the dog, but he'd probably just bite me so I let that one slide....  

[enjenjo]

We use an epoxy adhesive/filler from Ceiba Geigy to repair brake spiders on truck axles, it holds up well, but I don't know how a snap ring would affect it.

Any chance you could come up with a piece of aluminum pipe close to the size you need, and make an insert out of that? You could cut a section off, glue it into place, and machine the assembly, getting away from having to machine a ring.

[C9]

We use an epoxy adhesive/filler from Ceiba Geigy to repair brake spiders on truck axles, it holds up well, but I don't know how a snap ring would affect it.

Any chance you could come up with a piece of aluminum pipe close to the size you need, and make an insert out of that? You could cut a section off, glue it into place, and machine the assembly, getting away from having to machine a ring.

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Did think of the aluminum tubing/pipe, but it entails a trip to the aluminum store.  And they may not have it in a close enough size.
Right now I think I'm gonna give an epoxy a try, it's a non-critical deal and if if doesn't work, back to the drawing board.

[river1]

can you get at it with the tig torch head? if so fill it with a weld bead and remachine.

hope it helps jim