Actually aluminum tops aren't that expensive but for it to provide as much strength as a plastic tank it needs to be thicker. Moreover, the cost of welding that is more expensive than crimping.
The drain plug is screwed on, it will not pop. You have the overflow to the reservoir to take care of overpressure. Plastic tanks pop primarilty because of clogging.
And sorry dude, but in this universe, Copper outperforms aluminum in thermal conductivity by a factor of 1.7. It is also more corrosion resistant.





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