You might be able to cut the cost even further by investing in a balsa stripper:
https://www.hobbylinc.com/htm/mas/masma4000.htm
I've had one of these for years, and while I admit it gets more use as a model airplane tool, than a model rocket tool, it's paid for itself many times over.
LOL Bunny Ya beat me to it! that's exactly what I did:
Purchased Balsa sheet in all the various thicknessed needed for the job. I think I still have a file in the cabinet with a parts list and receipts...but I haven't looked at it in years!
Char:
My base is 1/2" MOD-2 plywood with 1/8" tempered hardboard sides and "ribbs" the split blast deflector was all make with 22ga Galvineal steel simply pop riveted and epoxied in place. the base under the Gantry was carfully cut to slip fit into postion with tow layers of 1/8" hardboard tung in slot at the forward section and interlocks strips along both sides. This worked out GREAT for easy removal for transport but very rigid seating in place. Remotor control gear box and connections to amphenol mulit connector cable lines were attached to the underside of the gantry portion base plate with rotator rods, bearing and power wiring and contact rings run inside the elevator shaft. and inside the right side front corner at the access platforms. I make the access platfroms swing into the level plates without sliding back...I didn't see the detail until far after construction.
As the patterns are more then 30 years old, I can't be sure what kind of shape they're in: They are I believe on 1000H clearprint trasing paper, and a couple of old OLD OLD Ozlid blue prints. If either have survived in the tube I'll try to wrap a set up and ship them to you after Christmas
Every multi Launcher controller I've built since Has alway has switch provisions built in to accomidate a new Pad 39 complex... it's still a dream to rebuild the unit. Since Next year is the Saturn-V's 40th brithday, and my original Satrun-v has been retired, Maybe it's time for me to try start a new setup as well
It might be of a little intrest that I logged a little over 1100 hours building the last Pad 39 gantry complex
Heres a few more OLD BAD poloriod pics for your viewing pleasure.