Wow! Great stuff. You must've been really immersed in this subject. I remember some of this from way back too. Before I got my engineering education I worked on the 747 production line in sheet metal fabrication and machining. The surface prep chem plant was right next to us so some of this is very familiar. But having had that experience, and having seen the handling requirements of the materials after they exited the prep site (a finger print in the wrong place was enough to scrap a part), I didn't think that this was very conducive to the light airplane industry, especially to homebuilding. As such, the primary thrust of most of my work in examining bonding agents and surface prep techniques was to eliminate as much of this as possible. I'd like to see this evolve in such a way that only basic surface cleaning would be required of the builder before the bond takes place. The most promising bonding agents I've seen thus far are the Methylcrylates (Plexus, Extreme, etc.). From what I've been told and what I've seen in our tests, as it cures the material actually does a bit of its own etching of the surface, negating the need for any significant prep work to be done on the part of the builder. So far, peel tests have demonstrated strengths that exceed some of my epoxy tests by at least a factor of two to three. The Methylcrylates are already used in the automotive industry for everything from bonding body panels to mounting door hinges onto the vertical king-posts. The aluminum structure of the new new Ford GT40 is reportedly all bonded with this material. But before I commit to any process, I'd like to see more test data so thus far I've been a bit slow in jumping on the bandwagon. But it does look promising.