You did make some good points decoded........ and true, a thicker base is inorder for aluminum. to five it more heat transfer mass.
As far as the corrosion issue. I ran an aluminum block for about 4 monthos in a mixed metal setup. CU rad, aluminum Res. brass fittings with dist. water and 3 oz of watter wetter per gallon. (no my system did not hold a gallon of water, it was pre mixed in a gallon jug) and I did notice a little grey discoloration in the water channel, but no biuld up, and no deteriaoration (man my spelling sucks, but I dont care) either way I would still recomend running 1 OZ of per gallon of good quality anti-freeze in any mixed metal setup. and yes, being made of aluminum would make them easyer/faster to make. therefore being more plentifull.
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