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Originally Posted by Andy Brockway
The biggest problem with aluminum will be longevity. Shifting on the fly will reduce this and the interaction during the mesh will also hurt. Lube with grease and bring spares. The issue I see is that the edges will round and/or burr causing problems during shifting. They should be fine for driving the gear once engaged.
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I have no experience with aluminum dogs, but I would stay away. As Andy mentioned above, the edges are likely to round. Once this begins to happen, you may see another problem occuring: the dog may be forced out of its mating gear. Dog gear interaction needs to be parrallel with the turing shaft. Any lead in our rounding acts like a cam, forcing the dogs apart while under a radial load.
Andy B.