Perplexed
New Member
Hee Hee Hee! So modest....but good!Oh well. If you really must follow advice - you'd better follow mine!
Hee Hee Hee! So modest....but good!Oh well. If you really must follow advice - you'd better follow mine!


Personally I would use layers of exterior ply to get the correct thickness, then cut the aperture. Then sand smooth and cover with epoxy resin and cloth, then fill and fair and paint with two-pack. Lightly sand to remove any brush marks then compound and polish. Time consuming but you will have a professional finish that will last for years.
Exposed edges are liable for delamination if not sealed sufficiently wellBuilding a solid block 170 mm thick would be heavy and a massive waste of material. A simple plywood box would do the same job.
A hardwood frame with an inset plywood panel on the front would work well, and the edges of the plywood would be protected by the rebate.Building a solid block 170 mm thick would be heavy and a massive waste of material. A simple plywood box would do the same job.
It would only be a frame once the aperture was cut! As for waste, ply is relatively cheap. I was looking for the easiest way to do it with few woodworking skills!Building a solid block 170 mm thick would be heavy and a massive waste of material. A simple plywood box would do the same job.