Another issue I am going to have to resolve soon and is a great question for metal workers.
The seat pan Vetter drew up has a 1/8" aluminum top which is bent on two sides for rigidness and connects to the two side plates via extruded angle aluminum (1") with machine screws.
Bending 1/8" aluminum, I imagine even 3000 serious, would be pretty hard for a nearly 4' bend. So I was thinking. What would be stronger. Bending the aluminum in a large radius (like over 1/2"), welding extruded 1" angle to the edge that needs it on the top of the plate. or simply fastening the extruded 1" angle to the edge with machine screws as well.
I believe there is a picture on my blog with vetter's suggestions and you can see my videos to see what I am talking about if you have no clue
