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I'm planning on having the components of a unibody structure made from laser cut plate and rectangle aluminum tubing. I don't expect to be spending more than $1200 on materials as aluminum is running in the $2.25/# range and I don't see needing anywhere near 500#'s of it.
Carbon fiber and fiberglass is beyond my skills although I have a general knowledge and and worked with them before on a limited basis.
I was commenting that at a later point I may opt for composite sections of body, but to begin with I will use the aluminum for ease of making changes as things progress.
Most small car unibodies are manufactured from 1mm steel stamped sheet, it's the shapes that give them their strength. I don't see where using .080 or .090 alum sheet with an occasional square tube here and there will yield any less stiffness.
I'm not rich and not looking to set new records(you never know though), but I'm pretty sure that with a bunch of Civic parts in a small aerodynamic and lightweight car I can see the mpg gains to be proud of along with performance I'll like.
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