Sorry to barge in on your thread (I did do an intro first).
If you go the aluminum route, you could use surplus highway signs. They would be cheap (relatively) and very visible at night! The alloy is usually 6061. Might not bend a 90 without crazing or cracking, but would probably do a tight radius OK. Pop rivits and 3M VHB tape!
Cool project.
Cheers,
Sq.
was also thinking about coroplast or 1/8" plywood, or aluminum plate, coroplast being the lightest, plywood being easy to work with, and aluminum being stiff enough that it would make the frame more ridgid, and because they are all self suporting they could simply be glued in place, and have sound dampening pads stuck to them.[/QUOTE]
__________________
|