metal filler a way to resurrect the aluminium, are any tough enough
Just re-reading this thread, Tim, and on your question of a new EBB or refurbishing the alu: Wellll, I have used J B Weld (a metal epoxy cold weld made in the states) for all manner of things over the years, and it's tough as anything, harder than alu or close alloys. BUT, I've only ever used it for
external crack-filling and repair, and occasional small joining projects where there's a large enough mating area between the two surfaces being joined. On an
internal arrangement like the EBB, I'd be worried about not getting the repair suitably filed/sanded down so that it's as round as the original (I have only hand tools for such jobs), with the possible result that the friction of the EBB against the frame is unevenly distributed, the adjustment rotation is thus less regular than it needs to be, and your possibility of slippage remains. Even more, I'd be worried about the whole affair seizing, so that you have a serious false economy. Easy for me to say, but I'd splash for a replacement EBB.
Then again, Jim just above has a trick plastic work-around!