>Blimey! Just like that.
Yes, well that was certainly the longest and most difficult part of the project. I gave it the gloss so I didn't entirely bore everyone with the details, but "relatively easily" was, well, relative. Mostly it meant that I was actually able to do it and that I hadn't had any catastrophic failures in the process. I know that some people go crazy making spinning tools by hot forging them and everything, but I got the how-to on making the right kind of tool rest, combination spinning and planishing tool, and cutting tool from a video I rented from Smartflix.com (Netflicks for nerds, and an awesome resource). I shaped the tools themselves with a grinder and then sanded and polished the combination tool. You should have seen the looks my neighbors gave me as the sparks went flying!
>I do a little metal spinning myself
Cool, what have you worked on? As I started reading and watching this stuff on metal spinning I got really turned (no pun intended) on to it. It's still amazing to me that someone can form metal (what seems like such an alien, industrial process) on a simple wood lathe at home.
>Aluminium: ask at the suppliers about what alloy they would recommend.
Too right. My supplier has been McMaster-Carr and I've been consulting their metal suitability chart. So far I've been working with 3003 because it has good workability characteristics, is okay for use around food, is corrosion resistant, and is a bit stronger that 1100. At first, I was worried that the walls of the kettle would be weak, which is why I chose the 3003, but given the strength of my mock-up and that it's actually going to be pretty hard to get the metal as thin as I want, that may not be an issue. The 1100 is supposed to have even better working and anodizing (should I go that route later down the line) characteristics, so I may make the switch.