Shown below is the fuselage of the dogfighter that was made by vacu forming PETG plastic and then bonding in the internal foam board and lite ply structure.
The PETG was a good strong light weight plastic as long as it was formed at the correct temperature. If formed at too high a temperature the plastic would become very brittle and shatter on impact. But if the temperature was correct the plastic would be impact resistant.
This was about the lightest of the solid thermoformable plastics that we could find.
You could also glass the inside of the fuse to make a much stronger and durable part. PETG will also accept paint if roughed up with sandpaper.
