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Thanks everyone, I really appreciate it. I'm going to throw the kitchen sink at it with a DIY silicone gasket, heli tape and either hairspray again or I might try liquid chalk instead, I've got some of that somewhere. Although, I don't know if there's a potential implication of something in the liquid chalk permanently binding alu somehow. Might just stick with hairspray.
I'll see how we go tonight.
Thanks again for everyone's input, this is why I love this forum.
Bump for still looking...