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The horns are not really a "framed structure with plywood", but they should be a "Stressed Skin" construction. Glue up everything you can.  The screws are just there to make the glue work better, and it's OK to leave them in. The idea here is to have a "monolithic" structure, especially including the skin (or, shell).  This principle is put to good practice with the "torsion box", which is by now a well-proven concept.  The braces should also be glued to the skin, to be part of it.  Since edge fastening with plywood in these situations is sub-optimal, the "braces" are really just as much "glue blocks", and they also provide better "bite" for the screws that pull the parts together so the glue can do its job.

I've also been thinking it might work best if you could "parge" (with mortar) the INSIDE of the horn.  Anyway, I think you might get better results with less material; under 1/2" should do it on the inside.

(and I agree with Jessie about the "flying bricks"; like Velvet Elvis...)

Best regards,
Paul S

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