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You might look at some of the manufactured siding products for your skin rather than 1/4” AC or loan. LP SmartSide has a wood texture already on it and is about 3/8” thick, so would save the sandblasting step. You could laminate it onto foam or use wood blocking
to help join the corners or add material for corners around your target. From talking to a carpenter who uses it, the material is flexible but durable - it can be notched without being brittle or breaking.</div>
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I think it comes in widths just under 6” /8”/12” that could be ripped to the widths you need.</div>
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Jim Dougherty</div>
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Production Manager,</div>
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Middlebury College Theatre Department</div>
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On August 31, 2026 6:01:20 PM PDT, Joe via Stagecraft <stagecraft@theatrical.net> wrote:<br>
>I am creating a target for a fake knife-throwing act. In particular I am wanting the frame holding up the target to look like it is made from 4x4 lumber that has a bold 3D weathered wood texture. I want it to both be structural, and lighter weight than what
4x4 wood would weigh.<br>
>My first thought was to laminate some foam beams with 1/4" plywood. Then, perhaps texture it by using a sand blaster on the wood. I know this technique works on wood planks, but plywood with its thin layers would likely not survive the method.<br>
>My second thought would be to do the above backwards. I.e. use 2x2 wood, and skin it with 1/2" thick foam. Then, manually carve the wood texture into the foam. It would be more subject to damage. But ,of course we can coat it with something to help prevent
that.<br>
>Another possibility is just to use lighter wood, like Balsa planks. I've never attempted this. And I doubt the wood would be strong enough where I attach any fasteners.<br>
>I think the most likely approach is to frame out a square tube from 1/2" thick wood boards, and use the hollow insides to help hide electronics and mechanisms.? It is thick enough to take some sand blasting, and be rounded on the corners. And it is easy to
screw attach things to the outside surface. On the negative side, it is a lot of work to gain a 50% weight savings of those pieces. Though, I have not calculated how much it saves from the entire assembly.<br>
>Any other thoughts?<br>
>-Joe<br>
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