Experiment with wooden construction as promised. Redwood PAR of a nominal 2 x 1 inches section actually weighs 10% lighter than an equivalent alloy of 40 x 20 x 2 millimetres beside costing a quarter of the price. It seems to be as strong, especially cross-braced by trusses as it is here... nonetheless am still likely to run with an alloy build albeit with a foam sandwich in the centre-deck.
Meanwhile I continue to grapple with the allowable dimensions for the fly-off in order to accommodate a form of 'phone-booth' for the passenger, though I believe I have a solution.