Re: Fabricating a new transom out of 2? box aluminum tubing
It's a more expensive/intensive way to go about it than just using wood, which is why the manufacturers don't do it. If you put it together like corrugated aluminum, then it should be stronger than factory.
The only thing that I can think of that would be a "potential" problem would be if the transom were to get damaged...how would a future repair be accomplished...
Something to chew on anyway.
Make a plan, and then work the plan.