I would suggest using some hardware store aluminum barstock, say 0.25" x 1" or similar. This is practically guaranteed to be 6061 or 6063, the most common alloys in use, and has excellent anodizing characteristics.
Like you said, anodize is an insulator. This means that it is physically impossible to have "100%" coverage. You aren't looking close enough. The pros have gotten real good at hiding the connection point(s).
Connection resistance obeys Ohm's Law exactly, 1 ohm of connection resistance will drop 1 Volt for each Amp applied, exactly.
You should add some old fashioned vigorous scrubbing to your cleaning process, you'll find that it works wonders. Perhaps M_D or Easttex can make some specific recommendations, since these guys (among others here) are anodizing for commercial purposes.
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