Discovery Process...
I tried aluminum cans also. Finally realized that the hassle of removing labeling (paint remover) and getting the surface flat was too much trouble considering that the aluminum alloy used will not temper to "soft" or "dead soft". It's good for some applications but can't easily be "worked" for many modeling applications. Conversely, tooling foil is dead soft and can be formed into about any shape necessary to produce a modeling aluminum analog.
I came to the same conclusion regarding the use of urethane glue. Thinning it a little with toluene makes it easier to apply...
+Gil
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