Sounds like a lot of fun!
My sons and I built a VW powered Baja Bug together, lot of fun!
They've been learning the basics, we're almost ready for more advanced stuff.
Hey, I wonder if you have seen this:
http://www.caswellplating.com/kits/aluminum.htm
I have used their blackening kit for steel. Worked great, till I tipped over the solution... Bummer.
Have fun,
Scott_bob