Brain is starting to fry, again!

This guy had problems with the concave surface of his ali profiles...
http://www.cnczone.com/forums/showpo...7&postcount=33

... his fix was a mix of long t-nuts and epoxy to flatten the face, but the area he was dealing with was quite small.

This got me thinking, could epoxy be used to to flatten all mounting surfaces on steel box and smooth over the dimension issues with ali profile? The above thread makes for good reading and at some point leads to this build...
http://oneoceankayaks.com/madvac/madvac_index.htm

This epoxy is amazing stuff, the two linked builds make heavy use of it to ensure the joins in the steel frames are true.

So, with enough epoxy, a precision level and a thick sheet of glass do you think it possible to true ali profile? The end result must be better than building with 1mm irregularities?

Two big problems:
1) The cost of ali epoxy, http://uk.farnell.com/araldite/arald...0ml/dp/1759545, need to add in the cost of a dispensing gun too, I think.
2) The fact that even with surface prep the special epoxy is not a guaranteed strong, long lasting join.

Since all I'd be using the epoxy for is to make the filling between two lumps of metal is it necessary to use ali epoxy? And indeed, am I obsessing over trivial detail ?