Ray,
Here's the thread link on my C5 Corvette based '60s era sports car project:
http://allmetalshaping.com/showthread.php?t=2264
While I elected to build the body with a material other than aluminum, I agree with the popular opinion in this thread that you should build yours in aluminum. I didn't have knowledge or experience with shaping metal when I started my project. Now that I do, and I would make a different choice if done today.
I too am taller than average (6'5"). I've learned the importance of having longer foot wells and larger doors to make it easier for me to get in and out of sports cars. I'd suggest you spend some time mocking up door openings while you're making a buck so you can "practice" getting in and out and make sure it's comfortable.
If by chance you're open to a body other than Scarab, like maybe a Ferrari 250GTO, let me know. I might be able to help you out with measurements, etc.
Best of luck with the project!!