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Here's what i've been doing for metal reflectors:


I use aluminum flashing for the reflector. The frame is made of aluminum angle and u-channel stock and strips of hardwood. I took off the end (which is made out of black acrylic) so you can see how it all goes together. The aluminum is flimsy by itself, but when it is all put together, it is actually really sturdy. I've doubled up the flashing in my recent builds to make it even more sturdy and it has helped. I also considered using a thicker gauge but it is much more expensive and harder to work with. The great thing about using aluminum is that it can easily be polished to a chrome-like mirror finish!
 
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