Okay, finally put it together.
Here's what I used:
Duct tape: $2
Foam Core: Free (thanks to David Whatley!)
Dura Spray Adhesive: $4
Space Blanket: $2 (an excellent suggestion by dquarles - thanks Donna!)
Screen Frame: Free
Okay, here was my thinking. Foam core is pretty flimsy and I wanted something I could put in my car fairly easily and take to location shoots. I was worried about snapping or bending the foam core in a moderate wind, so was thinking about doubling it up or putting some sort of stiffener in the back. Well, poking around the garage I came across an old screen that the dog had torn, and had an idea.
I cut out the screen, keeping the aluminum frame. It's roughly 36x36. I then cut a piece of foam core to go inside the frame, and the convenient thing about using a screen frame is that it already has a little "lip" you can seat the foam core on. I taped it in with duct tape around the edges, and then liberally applied the spray adhesive. Gave it about 5 min to dry, then set the crinkled up space blanket on top, smoothing it out as best I could. The space blanket is much tougher than aluminum (tear resistant). Just be sure to wad it up, smooth it out, wad it up, etc several times for maximum "crinkly-ness". After laying on the space blanket I trimmed the edges leaving about a half-inch. Then one more strip of duct tape along the edge to lock down the space blanket. I also added some extra duct tape at the corners to protect the space blanket from rubbing a hole from use and starting a tear.
I'm satisfied with the results, I now have a 3x3 reflector with conveniently located duct tape handles. The aluminum frame gives it a LOT more stability while keeping it lightweight. Another added benefit is that you an use fairly heavy clamps on the aluminum to keep it in place without damaging it.
I have a shoot this weekend (lil kid in the bluebonnets) that I plan to use it with, so I'll post the results afterwards.
Next step is probably one or two 3x4's for use indoors
It looks a little ghetto fabulous, but it's sturdy and stiff, and should be able to take some punishment out in the field. Plus if it gets destroyed I'm only out about $2 (the cost of the space blanket. I've got enough duct tape, foam core, and adhesive to put together 3-4 more...)
