You can probably use epoxy
to do the job.
What you will want to do is wire brush (preferably with a stainless brush) until all the aluminum oxide is gone. (The white flaky stuff.) Then take a nice heavy grit sandpaper 50 or less, and focus on the pitted areas to give something for the epoxy to key into.
Then take your epoxy product of choice, there are a few that work
nicely... JB Weld, marinetex... to fill in the low and corroded spots. It will take half of what you think it'll need to do the job, but mix up enough. I'd suggest slow or normal curing speed and not the fast stuff, so you have enough time to work
with it. The more prep work and time spent getting things flat will make the following steps easier, and increase your chances of success.
Once you have put a dollop of mixed epoxy on the low spots, take a piece of sheet metal that has a square edge long enough to span across the face of the aluminum housing, and use it as a screed to flatten the epoxy. Hold it at around 80 degrees and pull towards you. Go back and with a putty knife work a glaze of epoxy into small pits, nicks, or machining scars. Keep the epoxy away from the bolt holes!
Wait for the epoxy to cure.
While it is curing, take your bronze
end caps and lay them on a precision surface. Use some prussian blue, or color the part with a sharpie to see how flat it is. and lay it on a piece of 600 grit paper. Work it around in different directions without applying any pressure to one particular spot. Count your strokes one direction, rotate a quarter turn... keep on going. Look at your work, you want more than 80-90% of the surface to be flat.
A hunk of granite is best, but any machined cast iron table will work. Think table saws, or any piece of equipment
with the marks of a massive fly cutter
. Glass will work, but you need a flat surface under it or it will flex slightly.
If your epoxy is dry... borrow the longest widest single
cut mill file you can find. With no pressure on the file make a light pass across the face of the aluminum and epoxy. Do not cant, angle, or dig in, let it do the work. The shiny spots and smoth spots will appear... Only take off the high spots!
Now take some prussian blue, coat the bronze
end cap and slap it up against the aluminum housing. You want coverage in even band of contact all around where the seal will sit.
Repeat your light filing, of only the high spots (high spots are where blue has transfered) on the aluminum until the surfaces are flat to each other.
Your file is wide enough and flat enough to span the gap of the oring. If you have contact on both sides, assume that all is well in the world between the two stripes of blue.
Now, install your new seal. Check to see what torque specs are on the bolts, failing that... use a torque wrench and torque the bolts in a star pattern to whatever your elbow
says is good and tight. (You can also look up the bolt size in a machinist handbook and see what the torque spec is on the bolt... and cross your fingers that the guy designing the part did the same thing.
Hope this saves you some money!