Thanks in advance 🙂 I have some basic woodworking experience but I am definitely in over my head. That's ok though, I'm happy to have a nice learning experience! A few notes on the project:
- Needs to be as light as possible. Instead of using plywood or hardwood boards I want to use 1/4" end-grain balsa core (probably this specific one https://www.mcmaster.com/7810N122/) sandwiched with 1/16" veneer inside and out. I have no hands-on experience with either of these materials so my main question is will this sort of construction doom the project from the start?
- Needs to be weatherproof. The ideal coating would be cheap and environmentally friendly, I don't mind if it needs to be reapplied periodically. If I used something like tung oil or boiled linseed oil would the veneer survive in the sun and rain? Also would it have any hope of staying attached to the balsa core?
- As far as joinery/construction process my thoughts were to do kerf bending (backfilling the cuts with glue and sawdust) for the radiused corners. For the sharp corners I was thinking miter joints and possibly adding some 1/8" dowels to pin the joints together. In my head the construction process is fairly straightforward, but of course any thoughts here from those with experience appreciated!