Jeremy, How about, thinking oustide the box, like wot i do, make a body out of solid wood and take it to a plastics firm and get a shell vac-formed.
Light, strong and flat (ie not bowing, I should think a problem when trying to build something very light and relatively flat.)
Easy to glue bits to (as it would be styrene sheet)..Fairly cheap.. materials to build the plug, dead cheap, vacforming…shouldnt be too much.. have two moulded just in case.
With a bit of thought, you could arrange to have a recessed tray for the battery and gear “moulded in”, and perhaps have the top bit (lid) on the side so you get that in styrene as well.
OR… make the plug out of expanded polystyrene, and so the vacformed sheet can be very thin, as you leave the expanded poly in place and this would support the structure of the shell…. just carve out the bits you dont want underneath.. self contained floatation guaranteed… go large, have a big one!!
Food for thought, eh ??
Ashley