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Bruce, I do like your enineering capabilities! Option # 1 seems to be very much labor intensive and I think somethink like an overkill for what you want to do. Option # 2 makes much more sense to me, but you can easily leave out one layer of foam without sacrificing on the sturdiness of the whole thing. However, you need to cover the sides with some kind of fascia for protection. It´s a quick solution, but not a dirty one. And it won´t buckle, bulge or warp! It will also weigh much less than you calculated 25 lbs. I bet even less than 20 lbs.!
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