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Iron/Steel is cheap, strong, and easy to work. Aluminum panels might have to be thicker, but still could be done.

Say if a car weighs 3000 lbs (maybe a bit less with aluminum).

And aluminum costs $1 to $2 per pound...

Making a 100% aluminum car would increase the cost by $3000 to $6000....

There may also be requirements for rare exotics for alloys.

The question is whether it is worth that on a $30K to $60K car.

Fiberglass and plastics are also cheap and light, but have durability issues and haven't been widely accepted for auto manufacture.

Carbon Fiber is similar... a bit lighter, and also expensive.

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