You can always use a Mig welder with a timer to spot weld. I have not
tried it on aluminum, but think it ought to work better than most
resistance spot welders. If you are going to try a small riveted seam
panel, you might try a small panel with spot welded tabs. If it looks
crappy before powder coating, there would be no need to spend any
money having it powder coated. But if it looks good, I would think it
would be a lot faster than drilling and countersinking for rivets.

Dan



Ernie Leimkuhler wrote in message

Well I don't have a spot welder capable of doing aluminum, and the ones
that can are expensive.

I am trying to stay away from welding solutions because of distortion.

I might just try a riveted seam on a small panel and have it
powdercoated as a test.