<font face="Verdana, Arial" size="2">Originally posted by Evan:
Yikes. Lots of easy to ask questions with hard answers. First, hand hammering compound curves in aluminum is a fine art. For an example see here:
Laying up foils to make a composite sheet is possible but not at the home shop level. The Airbus 380 uses a new material called Glare made from multiple sheets of very thin aluminum interlaid with fiberglass.
Spot welding is possible for most alloys but will leave a pattern of marks. Cold bonding is also possible but the aircraft industry normally uses vacuum bonding in an autoclave.
The best semi-flexible adhesive for aluminum is polysulfide adhesive/sealant and is used on pressurized aircraft to seal the hull. It is totally compatible with aluminum alloys and has very strong adhesive properties. It's also a freekin pain to work with, has a limited pot life and stinks.
[This message has been edited by Evan (edited 02-21-2006).]