My brother is currently building an all-aluminium light aircraft (a Van's RV-4) - it's scary to see how flimsy each component is, and amazing to see how rigid the parts become when riveted together. Each fuselage & wing part is made of 1.0 - 1.5mm sheet aluminium alloy.
He will end up with a 200mph 2-seater aircraft that weighs over 200kg less than my Locost...
