I went with red pvc, so I wouldn't have to do any painting on these. Plus it won't be noticeable if they get dinged during the shoot. Our Techno cut all the fronts, backs and sides for them.
The side pieces all got mitered on our custom mitering jig that uses a small laminate trimmer to route the edges to the desired angle.
I pretty much went straight to bed when we got home, and slept really well!
Which is good, because the next project is another 7 foot tall cartoon shark!