Nice work, Loren! I'm going to file that disc-forming idea away.
I've got another project on the bench, but I'm going to wait until it's a little further along before posting any pictures. Main material is aluminum flashing.
For the poster below that asked about epoxy - In the process of this build, I learned a couple of things about epoxy since aluminum isn't solderable. You must rough up the surface to give it a little "tooth" or the epoxy won't hold. I initially used the clear "5 minute" stuff and as soon as I flexed the joint even a little bit it popped loose.
Thinking good ol' JB Weld would work, I ran into the same problem. It did hold a little better, but not enough to be trustworthy. I had to use 60 grit paper and really crosshatch the surfaces to get it to hold and I still wouldn't bet the ranch on the strength.
The same would hold true for brass. The surface is just too smooth.
Solder is quick, easy with a little practice and the right tools, and very very strong.
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