In one embodiment a method to form a load bearing antenna aperture comprises forming a honeycomb core structure having a plurality of wall sections, the wall sections including electromagnetic radiating elements, and wherein lower surfaces of the wall sections defines a first surface and upper surfaces of the wall sections define a second surface, positioning a back skin to the first surface of the honeycomb core structure with an adhesive layer which comprises a layer of adhesive film and a paste adhesive disposed on the layer of adhesive film. Other embodiments are disclosed.