Zack wrote:I was wondering if it would be possible to build it with GATORBOARD?
I went and had a look at the
technical bulletin on Gatorboard and I don't think using it is a silly idea. The description of the face material isn't too precise ("man made wood fiber veneer", "exterior resin system") but the strength data looks half reasonable (100 lbs held up by a 1ft width of 1" material on a 4ft span).
Zack, you'd have to work out how to make structural joints at the corners and seal the exposed edges. You could think about using a boatbuilding technique of joining the poanels with epoxy resin and glass tape - because the core is polystyrene, you can't use (cheap) polyester resins. And you're going to have to think what to do at edges like door frames.
It's time to buy a 1" thick panel (can you get given a damaged piece, or an old sign?), fit it to a rough frame (just some 2x4s on edge) and try hitting it or jumping on it. When you've done that, report back here, 'cos you're now the Gatorboard expert!
This looks like a lightweight version of the SIP panel system, if that persuades anyone else to have a look.
Andrew