Building a kit car need advice

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It's been a while since I was last here.  I picked a miller 185 tig last year and have been practicing on a few projects.  I am beginning to get quotes on this hummer kit car I'm going to do.Ideally, my goal is to make this rig lighter than original (10K+), lighter than the kit version(~5700), safe, while keeping cost relatively low.  The goal was ~11-13K for the cost.  This is what I'm building www.tremormuv.com just a soft top version seating for six.I believe I have three avenues to choose from:1. All aluminum body and internal cage - < 500 lb total for the body2. Aluminum skin with mild steel cage. - 1200 lbs for the body.3. All mild steel  - 2000 for the bodyCost right now for #1 is 4600 and #3 is 1500 somewhere in between for the #2.Anyone care to share any do's/don'ts or ideas for this build?  Thanks,Danno
Reply:Seems like a nice project. You've already hit the high and low points. If you build from aluminum, it's more expensive. Built correctly, the aluminum can be very strong. The new Z06 Corvette is an aluminum body structure. Again, you can build it from steel - it is cheaper but will be more heavy. If you're trying to keep costs low, it looks like you're answered your own questions. John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:I should have stated that the aluminum is 6061 or 6063 depending on the stock on hand by the supplier.
Reply:Sounds great whichever you choose.  Keep us posted.Various GrindersVictor Journeyman torch200cf Acet. 250cf oxygenLincoln 175 plus/alpha2 gunLincoln v205t tigLincoln 350mpEsab 650 plasmaWhen you can get up in the morning, Its a good day.Live each day like its your last.
Reply:Steel.... be a man ***************************************Lincoln AC225 stick welderLincoln HD100 WeldPak flux core wire feed welderThree of the cheapest grinders money can buy
Reply:I recalculated the steel weight.  If I use 1/8 stock, I'm at 973 lbs.  I can live with that.
Reply:I was told and offered a suggestion - use 14g and 16g mild steel for the build and it would save me $$ and weight.  It is about $100 less and almost 200 lbs less.So Here is my question:  What setting to set the miller 185 tig at?