It is a strong(ish) alloy it's why I went with it for the tests. How I looked at the material I considered it an alternative to sandcasting, it had about the same tolerances but didn't require a pattern to be made. So I went for it and it worked. The thinning wasn't as grueling as you might think with a bench grinder it didn't take too long to grind down (probably because of the addition of bronze.) You have to look at these things as a labour of love, a lot like carving a lug.
I agree about the bottom bracket, I didn't know that sort of product existed? Certainly not from Nova anyways. Could you send a link, it would be helpful. I haven't actually seen a shell with chainstays?
Aligning the holes after finishing the lugs was actually pretty easy, I mitred the tubes and then used the lug as a guide for the holes, and voila two perfectly placed holes. The only difficulty I ran into there was the holes were a bit small (it was my fault on the design end, I assumed tolerances that weren't possible) so I used a rasp to make them a hair bigger then getting the clevis pin in was a snap.
Well I'm almost finished the design work for the new set so I will send them off to be made, make some other stuff myself. The only issue with welding is I don't know how to do it lol... I could do fillets if I get a better torch. But at the moment I only have one that can barely do silver, and I'm assuming that for a BB I would want to do a fillet in brass?