Interesting discovery today was how to make thin strong laminated material for panels very cheaply, when you are around car boot sales or junk markets keep an eye open for an old hand operated clothes wringer condition immaterial apart from it needs good rollers. coat a sheet of 1mm balsa thinly with PVA and drop it onto brown paper and coat the other side and cover with brown paper then run it through the wringer a couple of times wiping off excess glue from the rollers in between each pass, lay flat and weigh down to dry, what you end up with is a thin strong panel that is not much heavier than the original Balsa sheet once it is dry but much stronger and with one coat of sealer and rubbed down with wire wool it is ready to paint,
regards, Terry