Biggest problem with laser cutting aluminum is the way it handles heat. It's weird. It disipates it so quickly you have to cut alot hotter. You end up frying lenses. It also tends to reflect the beam a bit which is also hard on lenses. You can combat this by D.A.ing or dying the surface. Then you also have to get into a really hard grade of aluminum to combat against garring from rocks and that sort of thing. So by the time you get that high grade aluminum DA'd and cut you have alot of expense built up. I've looked into it pretty seriously but I don't think the benefits can outweigh the costs. The only way I could do it is if I add a water jet to the equipment roster. So, not to say that it is impossible just hard to do for a DIY kit. Tigging welding them on would be the shiznitz. I also think I would have to make them thicker to be as rigid as steel so weight savings would be a moot point.