[abl1111]

I agree, wood is the lighest I can think of. Fiberglass sounds like too much hassle to build - it would be a lot of layup to make something that would need strength in every direction.

I was hoping one of you guys knew of some great 'stuff' that met the criteria.

I am still open for ideas though.

The original ladder was perfect - however not great quality. It looks like a it was a moulded pastic but there are a lot of voids in key areas (that's why my ladder failed, at least ). But, the design is perfect.