El Tel · 3185
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Why not just paint the aluminium one with a metallic copper paint?There are loads of options.I admit very few actually pass for real copper but good attractive results, hammered or smooth, are possible.And if you don't like the result, you can always strip it off and start again.I would suggest this route first as you will be dealing with a known quantity in terms of chassis strength, especially once it gets hot.
Since I haven't done exactly what you're doing, I certainly don't want to be responsible for what might go wrong!
2.5mm is only .0015" thinner than 2.54mm.2.54mm= .09998"2.5mm= .0984"Nothing to worry about.
There's no substitute for the heft of real copper though...
