Hi, wiz310, i would strongly suggest you stick with the stainless brazed boom, as tig welding aluminium with small sized tube will be very difficult and require a larger wall thickness, I used an aluminium boom on my project, bolted together, and the weight was more than what i can make a stainless boom, Using hypo grade stainless brazed with silver in my opinion, will give you the best result. I have done some tests on this and I will be changing my boom to stainless hypo tubing in the future as i can make the assembly for about 2/3 of the wieght and it will be stronger. Stainless also suffers less from fatigue
