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Re: Is Welding Worth It?
If you want to see lots of examples on how to weld thin sheets, google automotive sheet metal repair. It is mostly done with steel, but lots of YouTube video. Welding in such a way to minimize distortion is an art and science. For heavier weldments you have to calculate and allow for shrinkage. There is only so much that stress relieving will do.
One large scale example of thin sheet frames are airplanes. They are mostly riveted or glued and riveted.
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If you don't know what you should hook up then you should read a data sheet
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