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Youtube can show you how to make a spot welder out of an old microwave oven. With a 2-3' throat you could spot weld the whole thing. It would go faster than all that drilling and riveting (once the spot welder is made).*
Absent a female mold, the composite would require a lot more finish work than aluminum. Will it all be painted white?
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I've got 3 toddler bike wheels, and I'm thinking about something like all-thread or a threaded rod for the front axle. Maybe frame it with welding rod and fill with luan paneling triangles finished with aluminum tape.
You can see in the pic at Permallnk #59 there are removable straight sections before the rounded tail. Do you think I should Vee them together and drop the rounded section? A cut and two holes and I can make them any length for a fineness ratio between 3.14 and 3.72. Isn't 3.79 optimal?
*Maybe you should ignore that, will you be riveting aluminum to steel and/or wood?
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