Weight savings is the key here folks!

Part of the sheet is going to be used as a base for mounting, so it needs to be durable, but not "pressurized durable". I'm looking for the lightest material out there, at about a 3/4 inch thinkness. MDF and Particle are pretty heavy, higher density woods, and I wondered if anyone else had a secret as to something lower density or just lighter, but still as/almost as durable.

As a note, it will also be used as a trunk floor while trying to keep weight at the utmost minimum.

Please chime in.

 

Baltic Birch. Just make sure you get the 13ply for the box. You can get away with the 7 to 11 ply with the floor. If you can source it, you can use 1/2" for the floor. Birch is vey strong and relatively light when compared to MDF.

 

thanks mang. i now remember reading that on here from some thread. i assume the local hardware store would carry this? i'll check tonight.

 

No problem. They may carry it. I have had to order it in the past. They had it in 3 days, so it wasn't too bad.

 

True Birch is usually sourced through a cabinet shop or supply chain. This would be 7-13 ply and no 'plywood' in between. Most of the bigger stores .. Depot and Lowes have plywood with Birch Veneer, but try as IIRC some got lucky. It is also not dependant to the name 'Baltic' also referred to as "Russian' and some various others. 1/2" is plent think for the floor.

Also try locally sourcing some HDPE.

Oh and MDF is Not High densisty, hence the terms Medium Density Fiberboard.

 

I've used furniture grade regular 1/4" Birch Plywood obtainable from the local HomeRepot store and it worked great. I cut cardboard to get the dimensions as patterns and then made my playwood panels, lined the trunk with aluminum foil, laid in the panels secured with sheet metal self tapping screws in a few strategic locations and used expanding foam underneath it. Once it was dry, I removed the panel, filled the screw holes with RTV and shaved the foam I did not need. The foam helped to keep it tight fitting against the curvy floor without fastners.

Almost forgot.. cover the exposed surface with matching trunk carpet applied with 3Madhesive and wrap edges around.

 

yep, find birch if you can. doesn't dust nearly as much as MDF when you're working with it.

on the opposit end of the spectrum...the heaviest stuff i've used is trupan. now THAT sh*t is heavy!

 

I'd like to see pics of all of this please.