Yea, seems like you're on sound footing, there.
I'd thought about making a 4ft, 5ft, or maybe 6ft dish last year, but finally sobered up.
Was considering aluminum (extrusions or tubing), wood, and then cardboard/foam for the skeleton, and aluminum foil for the surface (backed by something...mylar?)
Maybe even a solid backing of the full diameter, then put in the parabola, and then fill the gap between the two with expanding foam to hold the shape.
Also thought about a tubular ring around the periphery of the dish... aluminum tubing?
...to make it easy to handle.
Where I live, it's pretty dry, so it would have been easy to water-proof against what little moisture we have.
Then, I started brainstorming with a buddy, and we thought about making a mold in the ground (or on a pile of play-ground sand), and casting a dish.
The guns that chop up fiberglas rope and shoot it with resin came to mind.
To make a more stable mold for multiple dishes, we thought about using concrete over sand...
Also, I seriously considered an offset dish, instead of prime focus.
Great for ease of handling, and fine for ku, but not so easy for C-band hardware, I guess.
Let us know what you come up with.