Attaching brass rods

[Lolwel21]

I'm finally getting to make some progress on a build I started way back in 2017!
I'm looking to attach brass accents to a curved choke like so:
Screen Shot 2020-03-21 at 10.45.23 AM.jpg

What would be the most forgiving way to do so, assuming access to powered hand tools and epoxy, but no access to proper machining tools? I'm aiming to make the saber duel-worthy (stage combat+).
To give some examples of tools I have on-hand, I have a handheld electric drill with a variety of bits, a dremel, sandpaper, a hacksaw... things like that.

[Forgetful Jedi Knight]

I doubt you’ll ever achieve something like that, you’d have to have custom work done on a choke like that with predrilled holes for the rods, and even THEN, I’m not sure if it would work or look right given the shape of the choke. You’d be better off using a choke with a flat choke and running the rods parallel to that. You could do that yourself, if you have long enough drill bits.

[Lolwel21]

Alright, thanks for letting me know how difficult that mod would be. I assume it wouldn't be any more realistic to sand / file / cut the rod to roughly the shape of the choke, epoxy it, and disguise the epoxy? Would such a bond be too weak, or is brass really hard to sand?

[Forgetful Jedi Knight]

It would be weak, probably look bad and would probably fall off with contact

[Lolwel21]

Gotcha.
Guess I may have to give up on placing speaker holes in the choke: those rods would be to prevent my hand from covering them, while hopefully looking somewhat attractive.
Do you think it might be worth testing the bond strength with epoxy and wood dowels, since it's easier to sand wood rods to shape, or should I just (give up and) leave the choke blank?

[null]

Hey Lolwel21

Do you think it might be worth testing the bond strength with epoxy and wood dowels, since it's easier to sand wood rods to shape, or should I just (give up and) leave the choke blank?

I say give it a shot; anything is worth a try. The bond strength of the epoxy is not really as much of an issue as the adhesion. Even if you can't see it, raw aluminum will oxidize slightly from being out in the open air - that oxidization prevents a good adhesion. They key is to get rid of that oxide layer before bonding. Try cleaning wth acetone, sand the aluminum area to be bonded, wipe again with acetone, and make sure you get everything "glued" up with in 15 or 20 minutes.

If you decide to try it please do it in ventilated area & wear gloves; also be prepared for a mess ...

- Steve