ORIGINAL: FliteMetal

Don't discount the strength of the linen, canvas, or paper based phenolic. You will have to have a conversation with distributors to find out the appropriate phenolic blend to provide the lightest overall weight yet the strongest structural and surface benefit. This is more complicated than it appears at first blush. You need to be careful, in your conversations with distributors to weigh their reponses so you don't fall victim to sales and promotional hype....sadly...

My local distributor is very honest and has been extremely helpful in determining the specifications for what my personal needs were. That was for a thickness that would permit me to "scissor" cut the formers I needed for hot wiring. That is completely different than a structural issue. You are thinking in the right direction. I make no assumptions about the appropriate or inappropriateness of phenolic for your personal application. I sought to simply introduce it into the dynamics of your project as an alternatice which can provide the surface with which to create the faux metallic surface.

Where I am headed for you is the Behr acrylic metallics which provide the finest faux aluminum illustion any opaque is capable of providing. These are easy to apply, low mass water borne metallics capable of delivering superior faux aluminum finishes when they are clear coated with Minwax clear polycrylic or single part automotive clear coat provide perfect reflectance to replicate aluminum.

These are found at Home Depot and provide you the lightest and easiest faux aluminum finish. While I obviously promote aluminum finishes with Flite-Metal for the finest look of the real thing... I appreciate your desire to achieve the lightest all up weight possible. You are so focused on weight at this point I am trying to direct you to the lightest method of achieving the look required to replicate the B-36 you have documented for replication.

This will enable you to accomplish the lightest possible, yet authentic appearance of a natural aluminum B-36. Yes, I personally feel you can easily manage the weight differential represented by Flite-Metal. But you have to achieve the next best scale illusion with the ability to use Behr's faux silver acrylic before you come to the realize you have the latitude to accomodate the .0022222 ounce to the sq.in. of Flite-Metal... The phenolic does not require priming to achieve a metallic smooth surface...simple light sanding ; )