All suggestions gratefully received....

[Bender]

Don't entirely give up on the welding. I worked in an industry where welding aluminium was common. It's often the case, the welded part is actually stronger than the parent material. Check out a good engineering shop.

 

Welding is not out of the question but on a section that thick it's likely to fail, ideally it needs to have the correct filler, be heated and most importantly a good welder.

If a supporting section can be added to the lower part of the frame it would help, I have had aluminium chassis welded in the past with varying degrees of success, the most important variable is the welder.

[Smithers]

Don't entirely give up on the welding. I worked in an industry where welding aluminium was common. It's often the case, the welded part is actually stronger than the parent material. Check out a good engineering shop.

 

Welding is not out of the question but on a section that thick it's likely to fail, ideally it needs to have the correct filler, be heated and most importantly a good welder.

If a supporting section can be added to the lower part of the frame it would help, I have had aluminium chassis welded in the past with varying degrees of success, the most important variable is the welder.

 

Agreed.