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More contemplation due
You already have time and money sunk in the project. Do it right, do it once.
Marine ply is cheap (<£50 for 12mm thick) and should last a couple of years with no maintenance. You'd need to do the maths on what thickness you need, 6mm is going to be roughly the same weight as 2mm aluminium.
gbj_tester
I'm not sure whether the price or weight is most disturbing, but my expectations of cheap plastic sheet were probably a tad optimistic. Smooth sheet is about £25 cheaper than treadplate though.
More contemplation due.
Ta.