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HHC
That sounds a bit easier to incrementally alter - I hadn't thought of fiberglass... Any idea what type of fiberglass? I have a load of this stuff lying around, as it was left over from some roof work:
It needs a resin to set (which can either be applied by spray or brush), but I could see it working in the way you described (but probably would need several layers because it is quite thin).
This seems like it would definitely be cheaper, lighter and more reliable than trying to use aluminium sheeting (readily available of course @HHC but getting the right thickness and alloy was my concern as I reckon with an alu frame I would have to solder as TIG welding would be too expensive, and brazing/welding has too high a temperature, I think).