You are correct about the weight. I'm in the experimental stage now putting shelves in my new(er) van. I've pulled them out 3 times already because I keep trying to improve on them. I considered mounting a 3'x4' bolt bin for supplies but scratched it because of the weight factor.
If the guy thats going to do the lettering will get on the ball and get started, I can make the tool transfer from old raggley Dodge to new Dodge with payments and stop thinking about it.
I like the dbl luan idea. It will be slick though. May want to think about some rubber mats to keep tools from sliding around while driving.
I ended up making mine from 3/8 ply on 2x4 a frame.
Rubber mats were not in my budget, I put 3/4 x 3/4 divider strips every 10-12".
I also considered coating the shelves with some type of slip resistant...stuff.
Cool seal might work?
). I'm making shelf framing out of aluminum but considering glueing two layers of luan for added strength. Not a lot of weight-just tools, tool boxes and the sort. I'll use aluminum bracing every 2-3' under the shelf for structural stability. has anyone tried one/two layers of luan? birch/ply would be nice, but with 88LF of shelves, that could get real expensive. was hoping to stay away from 1/2" ply b/c of the weight (5 1/2 sheets!) 
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