Made mine with 3/4 inch MDF the covered it in fiberglass. The viewing window was made with just a 1/2" sheet of polycarbonate but acrylic works too and its about half the price. As for prep I wanted my box smooth as a baby's bottom so after fiberglassing the box I used filler putty(bondo) and then glaze coated it getting rid of all imperfections then primered and painted with quality automotive paint! Not hard but does take a little time!
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