Man, I have to try this herringbone stuff. Ah, another project.... I'll never be bored. Good job by the way.
Do you start with standard aluminum stock or is it recycled from something else? Also, what do you use for glue?
I tried some aluminum flashing once and had a really hard time attaching it to wood. I scuffed up both pieces, used CA and gorilla glue and finally get it to stay together. I don't remember which eventually worked.
Thanks for the inspiration. And, yes, like tool crazy said, slow down buddy.... you already have a huge lead!