[nitrostarter]

I would drill the holes first and then seal everything.

As far as the Aluminum, I would take a test strip of balsa and seal it up and let it dry. Then see if its strong enough for your likings.

I have seen wooden boats run into rocks, banks, turtles, alligators... and nothing happen to the hull. I've seen then stepped on and the hull be fine. The epoxy hardens and strengthens the wood tremendously.