It's your fault, Willie! You made me do it, spend money, yet again!
You mentioned that aluminum solder and I had to look. Then, I had to look further and I found one with a 500F melting point. I couldn't resist and ordered it. It came this afternoon and, of course, I had to try it out. It actually works! I did a .... joint of 1/8 to 1/8 aluminum, some scrap pieces, then a brass to aluminum "flat" joint. Both joints are strong, maybe the .... joint isn't as pretty as it could be, but the point is it works!
I was hoping with the lower melting point, to be able to use a soldering iron, temperature controlled station, but it won't produce enough heat with the contact areas I can manage. I ended up using a small butane torch to get it to work, but it did work. Next up is a 150/300 watt soldering gun.
Cleaning up the flux wasn't too bad. I used 91% IPA on a rag and it did take it off. With a little practice, it doesn't "flow" like electronics solder, I think it'll work out for the DNA75 low
tank mods I'm working on.