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I have the same question myself - but had a slightly different approach.
What if a few layers of carbon-fiber composite were laminated to the metal? This would improve rigidity at a low weight cost. Two layers would also make a water-tight seal.
The foam would help reduce bending in situations where it would be compressed. The carbon fiber could prevent bending over long sections if it can be securely bonded to the existing metal, stiffening them.
Some modern race cars eliminate the metal frame completely...
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