Madmax, your definatly in for alot of work. TIG welding is an option, but you really don't need to weld it since it will not be supporting any load or doing much of anything other than a cosmetic peice. Brazing rods are available for aluminum, they are rods with a low melting point (700+*F, don't remember the exact number) They will work fine for you in this preticular situation, I use them alot in aluminum art and some custom grills. Just do a search on any search engine, there are hundreds of companies that sell them. Aluminum diamond plat isn't cheap or easy to work with so measure 5 times cut once and draw out what you want on paper before you start working. If you need anymore help feel free to contact me. I made a rear bumper for one of my 4wheeling buddies about 3 yrs ago out of diamond plate.
HK
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