This is an idea I've been kicking around for a few years. Basically, make a roughish aluminum casting that I can mill or CNC to the final form. The idea being that every possible part will be part of a single casting, so the only separate pieces would be the electronics, and the moving parts: tuning machines, and bridge saddles (I'd like to try integral, solid saddles, once I've cast a couple and know where to machine them for proper intonation.) It would probably take a few tries to get everything properly positioned, and I'd hope it would be stiff enough to not need a truss rod, ie: I could machine the right amount of relief, etc.
So, has anybody tried this, or heard of it, or maybe played something similar? Think it's doable or totally bizarre?
A few technical points.
1. The saddles are the part of the bass requiring the most mobility. Casting them in place would IMO be foolish.
2. Trying to make the whole thing, including neck, from one piece? Look up the dimensional accuracy specs for aluminum castings first. You may find it's too wide a variance for your purposes.
3. Aluminum is horribly responsive to temperature changes. Ask any owner of a Travis Bean or Kramer aluminum neck what they think of their necks in this respect. Dimensionally unstable as they warm or cool. Any introduction of a second material with different thermal expansion characteristics, such as a wooden fretboard or wooden rear inserts, increases the effect greatly.
3a. The same players often cite the unpleasant feel of a cold aluminum neck. From what I've read, they -never play the instrument cold, -get to the gig early, to get the instrument up to final temperature, -tweak settings if necessary (can't do without a truss rod!) - never stand in the sun.
4. Save for a "hard coat anodize", there's no common process by which aluminum can be made wear-resistant enough to serve as a fret. Once you eventually broke through the hard coat, it would be like butter. So, you'd need to use nylon-wrap strings only, replacing them as soon as you detected that you'd worn through the wrap and exposed the steel.
[edit] Looking at the one guitar with an all-metal neck, it's possible that they have a "hard chrome" plating over it. I think this is doable, with a multistage plating, aluminum->copper->nickel->chromium. This does wear well, although the wear characteristic versus a steel string point contact is fairly severe. Not cheap, though.[/edit]
5. Cast aluminum always produces cavitation. It can be controlled, but never eliminated. So, if you're looking to cast oversize and machine down afterwards, you've got problems, as this can only be done to a limited extent. The bigger the casting, the greater the cavitation.
6. It sounds like you're looking to make this as a single solid piece of aluminum. Aluminum has a density of .098 pounds per cubic inch. Do some figuring of your total volume, to see what your final weight would be. You'll notice that some of the aluminum-bodied instruments pictured are hollow, or have thin bodies.
7. Aluminum is getting pretty expensive in the past few years. Figure that into your reckoning.