Ok well it got the better of me so I went looking at your links above.

This may be a long-shot, but there's a sprayable product you can get that is designed to replace electrical tape. I think it's for use in hard-to-reach places. Some electronics stores should sell it, or be able to get it. It think it's called liquid electrical tape?

Anyway this stuff is supposed to be used for spraying on wire to insulate it, and cures by air (I assume it has a thinner in it that evaporates). It's about $25 a can so not cheap, but if it solves your problem then it will be money well spent. You would obviously need to spray it over something, so some thing like very thin alloy sheet formed to shape.

If you are doing that though, you could also just make it from alloy and powdercoat it for a professional finish.