I'm an engineer. I'll fall for it and be your design consultant. Based on your current criteria my chosen material would be recycled kebab wrapper. It is cheap and easily formed.
Joking aside, give us the design criteria and I'm sure you'll get some pointers.
Givi use plastic as for large numbers with compound curves injection moulding meets their needs. I doubt this project will run to tooling costs.
Leather is traditionally used for toughness and a match to shoe\horse furniture skills. Still a possible.
Aluminium can be brazed, riveted or bolted but the trade off is strength and the seal. Adhesives cost and need serious prep and test......
My next sidecar body might be wooden just as a way of trying out old aircraft technology.
Andy
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