This was posted before and I ordered a larger container. Cost me over $100. It sets up hard as a rock. Not easy to sand. Should the blue portion be as thick as peanut butter? What am I doing wrong?
It's $22 for a lifetime supply (32 fluid ounces, about enough for 200 stunt plane fillet jobs).
http://www.aircraftspruce.com/catalog/cmpages/superfil.php The only sizes they have are the quart and *3 GALLON* sizes, I assume you didn;t get that. This opposed to the ~$20 for the tiny little 4 ounce jars of Epoxolite that we used to get. I forget what Aeropoxy Light cost.
It's not a easy to sand as some other wood fillers, like Elmer's Fill n Finish, spackling compound, or something like K&B Super Poxy Primer. It does set up like a rock, but a really soft rock. It's like Epoxolite but vastly easier to sand, to the point you can use it as a regular filler in some situations - unlike Epoxolite, that you pretty much have to form into the finished shape before it sets, or woe be unto you. Both parts are about the consistency of peanut butter or cake icing, and that's what you want - it's filler, not regular epoxy with something globbed in it.
I expect that we are not communicating or you are attempting to use it for something the rest of us wouldn't. I use it for fillets and, recently, as a filler over my stabilizer repair. In the latter case, this consisted of spreading thin over a relatively large area, and I had no problem sanding it down to feather edges using Perma-Grit files and then regular sandpaper, on a 1/32 balsa over foam stabilizer.
I probably *wouldn't* use it as a filler over wide areas of soft balsa as a rule, because it is a lot harder than you would want for that application. But it works fine for filling pinholes, divots, etc.
Epoxy and microballons has it's place as an adhesive, but as a filler it is the very last thing you want, far too gummy to sand and runs all over the place even in the best conditions, Charles' careful evaluation and relevant endorsement notwithstating. It's also not nearly as stable over time as SuperFil, with all that glue fraction, it shrinks a little (although nothing like as much as air-drying products like plastic balsa or other dope/sawdust concoctions, or Squadron putty).
Brett