Amen to that! Been Googling my a$$ off since it happened and have found lots of threads of people's covers failing. It's really a shame...
I can understand your reasoning for aluminum vs. steel with regards to wear, but are you concerned at all with the aluminum fatiguing or bending in the long run? Just a thought I had as I was reading and looking at pics. Thanks again for the help! Could you post a pic of the final product if you have it handy and don't mind posting it.