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I got my aluminum sheet ordered today. I used a local metal supply house that has no minimum quantity order, Midwest Metal Warehouse. They're only a few miles from home and they'll probably have my order ready tonight. I got a 24" x 24" piece of 16 gauge (.06") aluminum for $53. That should be WAY more than enough, and I'm thinking that 16 gauge will be a good thickness. I want it to be able to hold up to the pressure from the cooling system without ballooning out. I had looked at some .025" aluminum at the local big box store, but it was really flimsy. If this stuff isn't thick enough, I'll just braze some ribs internally (ideally) or externally.
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