Colin, How about constructing a Frame backing out of a rigid but light material like Aluminum? You can get Alum in various lengths and shapes. For instance, you can get it in tubes, solid cylinders, square tubes, U-channel, L-bracket, etc. It is in varios sizes too. You can purchase said alum from internet sources, or even locally from a place like Westbrook Metals. The frame would be light and rigid, and then you can go back to using a lighter substrate like the hardboard (like pegboard without holes), or whatever else. The hardboard or plywood or whatever substrate can be mounted to the frame via bolts and nuts, and the Plas-Tex can then be mounted to the substrate. I don't know if you were planning on doing the KBK goo or painting this, or just going with the Plas-Tex alone for the surface. Then just as you mentioned before, the trimwork around the border can be mounted to the edges of the screen. Just another thought. My DIY projects. Been drawing up dimensions on a few things: -- A shelf to raise the T.V. up 13 inches to put my new center channel under it. -- Stabilizers to go underneath my new tower speakers to give better side to side stability. -- Speaker stands to mount my new rear speakers on. Speaking of the alum. above, I'm actually thinking of using some of the 2" diameter hollow tube stuff as the "neck" of the speaker stands. They are made of 6061 alum, and can be polished pretty easily. Then doing top and bottom pedestals out of Birch plywood with veneer banding around edges and staining. Then some spikes from some place like madisound.