Dave - your spot on about the work hardening. The aluminium was basic garden variety 5005 H34 which is "half hardened" and soft to start with. I was worried is was going to be too soft and thin and easily damaged. No way, once it has been work hardened by forming with the English Wheel it is very tough, rigid and springy - bloody perfect. I did not anneal the ally.
I did use the tool and cutter grinder to true the wheel as I have it to use. You could do the same by setting it up between centres in a lathe and then holding a router or die grinder in the tool post. Very important to protect the bed from the grinding grit. This cheap English Wheel was crap quality but after a bit of tweaking the capabilities have exceeded my expectations. ;D
Cheers
Tim