"Clinch Nuts"/"Nut Serts"
Nigel,
I know that it is not original, but the next best thing is the modern "clinch nut" which is, as you know, a nut which can be riveted into sheet metal. Your friendly fastener shop will have a whole range of sizes/head detail. You may consider buying an insert tool - a fancy type of "pop" rivet type gun. Hint - don't squeeze too hard- you will break the hardened mandrels!
I have used fire resistant board when silver soldering my prewar brass windsheild frames together - I am not sure of its specific trade name, but it is black and it is heat resistant ie I can silver solder brass sheet either side of the fire resistant material which acts as a distance piece for my brass surrounds - the material is inert in the chrome bath. One could put the heat resistant material as the "meat" in the aluminium sandwhich.
I guess that the next best solution would be to use marine grade aluminium panels with suitable stiffeners/cross breaks pressed into them as per other sports cars.
Brett
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