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Re: strong composites for belly pan
A couple ideas:
Carbon Fiber with balsa core.
Carbon Fiber with honeycomb core.
Fiberglass with balsa core.
You can find almost any composite/core combination you'd like. We used a piece of fiberglass/honeycomb core for our 2005 robot electronics board. It is very stiff, light, and strong. Can be a little pricey though. Taking the 1/2" balsa-cored carbon fiber as an example, it has a density of 0.0125lb/in^3, about 88% less dense than aluminum.
If you get a little ambitious you could make this sort of stuff yourself, it's not terribly difficult.
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