I will soon be ordering sheets of Kydex to form the outside structure. Kydex is a thermoplastic foam that can be molded over just about anything and upon cooling, is a very strong and rigid material. It's usually used in the creation of pistol holsters. To reinforce the interior, I will be using struts made from stainless steel, which I already purchased. Making the positive wooden mold soon, stay tuned!

Examples of Kydex projects: http://www.odellstudios.com/2012/10/custom-kydex-projects.html

Where I prefer to buy Kydex: http://www.knifekits.com