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Automix is pretty cool stuff. I would use it and body filler to make the sheet metal attachments but still weld the frame. I would use the method shown for automobile roofs. I would stop about a 1/4" short and use body filler to complete the seam. This can then be sanded and blended and when...

I would assume you are thinking that 3/8" ply is your target thickness. Using a good plywood and maybe bolting a framework to the inside of the box I would think you could keep it pretty rigid. A 1x1 L channel would not be too intrusive.

WarrenD: Contact cement used for counter tops would be my first step. You will also find that plywood alone probably will flex too much you will need in my opinion to build an internal frame with 1" angle and fill with ply. I would start by building a simple box frame and adding diagonals to...

I would think the most economical material would be steel over ply backed with steel. Think sandwich or clad board. It would be alot of fabrication but frame with 0.5" tube and weld sheet metal to it then fill in voids and weld the back panel would make suitable armor substitutes. Benefit...