I've thought of doing that too to make a tubular aluminum frame. I saw several problems:

1. Saddle joint - the 1/4 in tubing would have to be jigged and then each joint cut at the right angle and then relieved to make the saddle.

2. Thin wall aluminum tubing is pretty hard to get in long lengths around here.

3. Have to learn how to weld or braze aluminum quickly and neatly (I don't think I need to learn another trade!)

4. Each joint would have to be fitted, then taken apart and cleaned before welding/brazing to get the oxidation off (am I right on this?)

5. Any kink in the aluminum would seriously weaken the structure, so a hard landing could require a LOT of splices and repairs.


Sooooo - I'm building an 8' wingspan Stearman out of dowels (which I know how to work with). This is a Barron design, so it's almost true scale but with all the gussets etc., it won't look that way .

I am going to make aluminum sheet metal parts to cover the balsa, but that should be relatively easy with thin stock and the balsa backing it up. Might go with fiberglass and score the panel lines after priming to simulate the panels and screws/rivets.

I could see doing one out of aluminum rod stock and donating it to a museum for a MAJOR tax write off.