It's done. I found that small pieces of sheet aluminum are available in the hardware store as flashing - I cut the vane itself from one of these sheets. In order to lighten the design, I made the vane considerably larger than in the Mark 1.5 version, and positioned it closer to the pipe cap. The net result was that I needed one third less counterweight on the front, making the entire assembly considerably lighter.
The only tricky part of the aluminum manufacture was attachment of the vane to the aluminum rod. Unlike with brass, I couldn't solder the vane to the rod. Instead, I made two close-together folds in the bottom edge of the vane such that, viewed end-on, a triangular space was created - one a little too small to accommodate the rod. Then I applied epoxy and wedged the rod into that space. It's solid.
|Mark II Vane|