Building a cage! Need advice!

I'm going to be building a very large cage for my GCC. The idea is, for the days when I am gone for extended periods of time, I can put her in the new cage, and she will have more room to play, fly, etc. Conditions I want it to meet: room for several perches and toys, room to do a bit of flying, and still small enough to be indoors. Is this even possible? If anyone has built such a thing, I would LOVE pictures and input.

we built quite a large flight cage for my birds, just this past summer. I envisioned it to be large, but when we were finished it was HUGE. It stands almost 7 feet tall, from floor to ceiling, and is divided into 4 large sections....you probably don't want yours that large, but each section is a good size. 2.5ftx2.5ftx3ft high.
we used non-treated wood, hardware cloth, and about a zillion screws, lol.
each section has it's own wide door,on hinges, with a slide lock.
I place newspaper down on the bottom in each section, as there are no trays...and it works fine, also has castors on the bottom to move this monster!
my nephew who is 17, built this for me, which was his first big project and did a great job.
my birds love the room to fly around, and it's fairly easy to clean.
although some people may not want to use wood as it can harbour bacteria, mold, mites, etc...if not kept clean. I spray mine with A.I.L. every 3 months or so for prevention, and is not that hard to clean, a vacuum does wonders
1st pic:my nephew is almost 6 ft tall, and is just getting the first door on
2nd pic: completed and in my bird room...sorry for the picture, I but it was so big I could not fit it entirely into the camera lens.

I was thinking of using PVC pipe as a frame. It's not pretty, but as of right now, it doesn't need to be. She'll get a fancier one when I'm done with school. The main thing is that I want it to be large and transportable. I want to be able to move it outside in the summer, so she can enjoy the outdoors safely. My main concern is what I will use for the "walls." I want something that won't rust, but I feel like she would definitely chew through a screen. I think there will still be a screen, to keep mosquitoes out in the summer, but I still want sturdier bars. Ideas?

Perhaps this: 3 ft. x 15 ft. Black Hardware Net-751397 at The Home Depot

DIY scares me.

More than manufactured bird cages.

For the same reason.

Unknown materials used in cheap cage bar material and/or coating.

Yup, it's the L-word:

Lead.

Birds love to gnaw - the might never get through wood that thick, but the materials being sold on the cheap just scream "lead and nickel" to me.

I'd rather buy a cage, complete with certificate claiming it's safe - so if the bird dies and the necropsy reveals lead or other toxic material, the manufacturer of the cage could be sued out of existence for misadvertising, thanks to their lies meaning the death of (well, if one bird dies this way, there must be others out there with the same horrible and preventable situation)...

Oh, dear. I didn't think about lead. More research will have to be done. Thanks for the heads-up!

Lead and zinc, which is anything galvanized. I have heard of people weathering galvanized products and people seem to use them in aviaries without a problem, but I wouldn't risk it, especially in a cage they are in all day.

If it helps...

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There are a lot of websites out there on how to build an aviary as well as books. Birdie Buddy can even tell you what to buy and where to buy it at. The rest are custom cages/aviaries that you can buy.