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Aluminum sheet metal worker here.
I response to above thoughts on material choice.
I spend most of my day cutting and welding,040 3003 grade aluminum. My cost is around $0.90 per square foot, which isn't much different from my cost on 0.32 mild steel which is around $0.95 per square foot. You can totally MIG weld, TIG weld, and spot (resistance weld) all 3, however you do need a lot more power to do the aluminum. I've also done fiberglass work and definitely prefer working in metal, but that's just my skill set.
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2016 Tesla Model X
2022 Sprinter
Gone 2012 Tesla Model S P85
Gone 2013 Nissan LEAF SV
2012 Nissan LEAF SV
6 speed ALH TDI Swapped in to a 2003 Jetta Wagon
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