LJ-MosinFreak-Buck
Member
Well I think I'll be going with the Titebond III
I would say go with your typical Aliphatic Resin (Titebond and similar products), especially for a prototype. Just keep in mind that it is not waterproof and may soften with prolonged exposure to moisture. You should be alright if everything gets sealed really well before going into the field, but something to be aware of.
Make sure the surfaces to be joined are as true, flat and square as possible to provide the absolute maximum surface contact. Titebond doesn't fill gaps well, so warped surfaces may not hold the best.
I would recommend having a way to clamp with even pressure along the entire length of the joint or glued surface. I don't think you need superman levels of force applied, but again you want to even out any surface deformities and eliminate any small air pockets. Even with an evenly applied thin layer of glue I would expect to see it bleeding out of the joint when clamped. The nice thing about the aliphatic resins is you can clean them up with a damp cloth or sponge while they're wet.
I can't imagine typical recoil shearing the bond under normal circumstances, but I suppose it's possible. In testing the prototypes I would watch for any signs of the joint(s) coming loose and reevaluate from there. And if I remember right the resins have more potential shock absorbing properties than epoxies, but I haven't used epoxies much.
As to the furniture comment, most real old chairs squeak and are coming apart because they were put together with hide glue, like hide from horses, not with a resin. Hide glues shear easily, but can be as easily repaired. When used properly resins can be quite resilient.
FWIW, my background in woodworking comes from spending a year in a stringed instrument repair program. You have to know what needs to come apart, what needs to stay together, and what to use where to achieve those results.