[christofoo]

I almost forgot, another method may be aluminum panels - simple curves only (not going to hydroform here). Not sure what thickness I would need, but it runs $1.7/sq-ft and up. I hesitate to go this route since the Aerocivic is built that way and didn't pass the wife-test (sorry Basjoos, it's beautiful to me). Still, I wonder if I could make it look good if I could stick to a radius bending frame (similar to the thermoplastic option #4). It seems like thermoplastic would be easier though. I'm imagining forming a large sheet over a conduit frame, then using a hot wire cutter to trim. Hot wire > jigsaw > tin snips. Even if I used a jigsaw on the thermoplastic it wouldn't deform and take on weird imperfections the way aluminum might.

I don't believe I've seen any forum members use aluminum "successfully" though.