Wow, I've only been here a week and I found a thread where my own experience is relevant. If I may, I've been building aluminum boats professionally for about 5 years. I just left off it a year and a half ago to start building my own boat.
We built water taxis and planing trawler-styled yachts to 45'. We installed Volvo D6s so I can't speak to bonding prop shafts and the like, but the zincs are different and, yeah you have to be very conscious of dissimilar metals and stray current corrosion.
The problem isn't with stainless (dropped screws, etc) but more with wire trimmings. ABYC actually requires that any electric terminals attached to aluminum must be tinned (they should be regardless...) We had threaded spuds welded on to the hull for thruhulls and threaded stainless nipples into them, so no brass or bronze and uber-strong. The zincs are specific to aluminum as well.
The biggest problem was getting the
paint to stay on the hull, which brings me to aluminum oxide. Yes, it's damn near hard as diamonds and nonporous (corrosion doesn't escalate as it does with steel) BUT the oxide isn't bonded very well to the substrate (uncorroded aluminum underneath). Essentially, the
paint bonds to the oxide and the oxide lets go from the hull, taking the paint with it. We wound up having to sand and etch prime it, and often there were still bubbles resulting from any scratches in the paint. In these waters, there's loads of deadheads so the paint shop was always busy.
The solution was to leave it unpainted, as we did with the workboats. Abrasion will rub the oxide off but it does re-oxidize really quickly. In areas of frequent abrasion like hawsepipes, the aluminum eventually gets polished to a mirror shine. As long as the boat is 'used', this polish is maintained and no corrosion forms (I don't know why).
Personally, I would never get an aluminum boat unless I was staying in waters near yards that had experience working on aluminum boats, including welding. That, and it sounds gawd-awful when you're on plane: we wound up spraying in 12" of foam to to try and kill the noise, but it came off in big chunks because it wouldn't bond to the metal.
Oh, and aluminum is a great heat-sink if you're in cold water....
My .02