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Thanks for the replies.
The elastic modulus of aluminium is more or less a third of steel, however so is the density. When you divide the elastic modulus by the density you will get the specific modulus [Nmm^3/kgmm^2.] Due to the difference of a factor three the specific modulus is the same for steel and aluminium.
It does mean that the actual steel sheet should be a third in thickness. Possibly the biggest advantage of aluminium is its corossion resistance.
As mentioned earlier by chapmanite deformationes due to large unsuported sheets should be avoided. The deformation can be reduced by the well-known circle structures, altough not fully. The best would be to add some sort of fill-material, which doesn't nessecairely have to be a honeycomb structurized aluminium. Suport structures could be added aswell.
The Elise has an aluminium chassis as well. It features two large side beams, these are extruded and slightly bend. A nice feature is the use of glue to save weight.
In terms of a DIY job I would recommend a tubular spaceframe. I think an aluminium tub would require quite a bit more research to make it work.
Let the discussion continue.
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