My project is a compound curved, 3/8" thick 60" long aluminum bracket to fit over the top of my transom. I will be mounting some custom aluminum davits (the white part in the photo) to it. I cut the aluminum and bent it to shape, but my 200 amp TIG would barely blemish the thick aluminum. My buddy has a HUGE Miller MIG with a 30 amp spool gun and he effortlessly welded it up for me.
My advice would be to mount the SS tubing with custom 1.5" thick HDPE brackets. HDPE is really easy to machine with wood working tools and is perfect for exposed boat parts.
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