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@jdmitch
ok, ok it sounds like I f'd up, I am willing to admit that I was not aware of the stress risers issue of holes/scratches, and did not consider that when I started removing the aluminium - I was just trying to get the track end to sit flat on the inside, thinking this would distribute any pressure more evenly, thus decreasing the stress. I would have thought even distribution of pressure was the more important physical property rather than the potential damage to the structural uniformity of the aluminium - which, I don't actually think I have compromised that much. I concede I may be wrong on that, but I maintain there is a method to my madness - I am not just dicking around for the hell of it, though I can see now that the time I've had to spend on this is disproportionate to the benefit of the change I'm making.
In any case, I don't think the situation is beyond salvaging, as the thin-ness of the aluminium should be compensated for by the steel, so ultimately the thickness will be significantly thicker than it was originally. I will likely have to reinforce what I have so that it isn't simply the track ends bolted onto the other bits, but I think it can be made structurally sound enough...