Super Beetle Diet Plan

[chigger]

You can use the cheap thin pans, gas tank, fenders, decklid etc, and maybe have them acid dipped to thin them out. The doors and mechanisms are quite heavy. Cut out the floor pan bottom leaving a 1 inch lip and replace the metal with the same thickness of aluminum rolled with an X pattern. Lexan windows should work in pop out frames if you cut them to size and use some spacers to take up the extra thickness. Aluminum bumpers with aluminum brackets. Just some more ideas.