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Old 07-20-2013, 09:08 PM   #55 (permalink)
freebeard
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I'm going to try this with one of my sample pieces: Cut back one aluminum skin and the plastic middle about 3/4-1" along the edge, lay in a stiff piece of aluminum wire I have, and wrap the other skin over so it laps 1/3" or so on the other side. Epoxy or solder the seam.

Drill the holes for the fasteners and dimple them so the bolt-heads are recessed.

What could possibly go wrong?
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