Hey Daox,
This is going great, man, really awesome to watch you going at it. This was the exact idea I had a while back when I was thinking about doing this. Of course, then I figured out that hypermiling when most of the driving I do is in a fair bit of traffic is pointless. I think I MIGHT still do a mod like this, though, and maybe a few others.
Might I suggest perhaps covering the entire thing in fiberglass? That would really stiffen up the backside of it, keeping it rigid for work, but very lightweight.
The fiberglass, by the way, is definitely the missing component insofar as I'm concerned... I had experience trying to do molding with this stuff - no way for anything large and flexible!
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