This is a
terriffic project, kudos to you both. My suggestion for the 'concrete block' is to make a block-sized box from expanded polystyrene foam sheets, spray it with a coat of varnish, then a layer of stucco... voila! ...a "one ton concrete block" that you can amaze your friends with by lifting it off the back one-handed

Additionally, make a secret hinged lid in it and it could double as a super-sized esky