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Yeah alu filler would be easily sandable to shape, just as soft as aluminium tubes.
In lieu of sugru you could also use formcard from london's own Peter Marigold
https://shop.storeprojects.org/store-store/formcard-by-peter-marigold
Glws
Thanks all - a few good options here! I will start with aluminium filler on the basis it sounds like it might be able to be sanded down flush to rest of frame. Might post on the projects thread when I start this build.