Thanks for the update Q. Glad the TB is getting the job done for you again.
Can't really tell from most of the photos but it almost looks like your welding in short circuit mode rather than spray as it should be with aluminum. In other words - need more power Scotty! Should sound like a hissing noise instead of frying bacon. Probably something in the realm of +/- 26volts and lots of WFS (Wire Feed Speed).
Keep the updates coming!.