[Aussie Mike]

I went with alloy because I figured machining up all the fittings to weld to it would be a pain in stainless. Much more stuff available in aluminum in that department.

Usually when I buy materials like aluminum bar stock and sheet I buy extra because I know I'm going to use it in the future. I bought a couple of sheets of 2.5mm and a sheet of 1.6mm. I figured the baffles are only containing the fuel movement and adding a bit of bracing so don't need to be so thick and add extra weight. There will be quite a bit of baffling inside.

Cheers