kscmpr54 wrote:Thank you, Tony, always learn lots from your posts. With that in mind,
it looks like fiberglass is the route to go. I'll get some
practice on a tongue box before tackling the whole thing. Hopefully this old dog can learn some new tricks.

kscmpr54, this sounds SOUND
the term FIBERGLASS can be confusing for some
those who shop at the big box stores see fiberglass resin and cloth available for cheap compared to the stuff boatbuilders use
the stuff sold at the big box stores is POLYESTER RESIN which is not intended for sticking to wood though some have used it and been lucky
it was developed MANY years ago and is still used in the fiberglass boat manufacturing industry
butt that's for sticking glass fibers to glass fibers when molding parts
for wood you need to use EPOXY which is quite friendly with wood and can be altered in viscosity by adding thickeners such as WOOD FLOUR to make the slurry to fill the glass cloth weave after it has been applied and thicker to use as an outcottonpickingstanding glue for wood to wood joints
when mixed even thicker it can be used as putty for filling holes and building up fillets for smoothing out corners
a very good and reasonably priced source for epoxy and fiberglass cloth / supplies is
https://duckworks.comyou can call them and tell them what you are doing and they will walk you thru the ordering process
the company was started by a home made/plywood boatbuilder and still carry's on in the same trustworthy fashion
BON CHANCE
sw