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Good luck Roger. Work looks great so far. I am currently making an aluminum hood, doors, and decklid for my ERA. (Turning it into a hybrid) For what its worth, I found the key to welding the aluminum is in making sure you continuously dab the rod into the puddle...and keep moving. The "cold" rod sets the weld and keeps you from blowing holes in all that hard work. I use a Henrob2000 (DHC) which makes welding a lot easier. Ron Fournier at Fournier Enterprises has some excellent video on welding sheet aluminum by the way.
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