If one is going to make the gills out of tin plate then I would think that dipping would be the best way of soldering as it will protect the cut edges which would rust very quickly otherwise and would not take paint very well. As we are not talking about a great total weight of material, would it be better to make the gills out of copper or brass ? Better thermal performance, no corrosion, and one could use solder paste.
Any commercial press operation buys the material in coils of the width required which is fed into the punching machine through rolls that straighten it and a gripper that advances it one pitch per cycle so eliminating more handling.
Happy Christmas everyone,
David