Hi, thanks for those posts, these are very useful insights into the problems I will have to overcome, and problems that i wouldn't have thought of on my own, thanks to all who have posted on this topic.
A message to Morben guitars, what do you mean by a side angle necessary to determin how the aluminium will affect the building of the guitar?
About the Tune-O-Matic bridge, I have seen a TOM on a bolt on guitar before so I know it can work, plus luthiers I have spoke to haven't mentioned any problems with it.
The Mahogany body will just have a protective lacquer on it, thats all i will specify to whoever builds the guitar, unless anyone has specific ideas of what should be on the body?
I will no longer go for aluminium on the headstock, just a silver paint to sort of match the body, oh and I don't want to silver paint the body before anyone mentions it lol.
Does anyone know how I will blend the edges of the guitar together where the aluminium sheets meet? Will a file do the job, or more than just a file needed?
If theres anymore problems people can see with this then please say as I would like to hear any suggestions. Once all the technical stuff is out the way its just a case of carefully cutting the aluminium and the pickup holes and bridge holes etc and carefully correctly placing it on the guitar.