Looking for lightweight composite panel product

[Duane King]

I work as a designer and a builder for a local children's theater. I am always using luan plywood to make scenery elements. If I need something to curve, I use 1/8" luan. If I want something that is dimensionally stable and strong, I use 1/4" luan backed with 1 x 3 pine framing. This product is cheap and easily accessible at the local Home Depot, and it meets the budget requirements of my boss.

But I want something more.

I design scenery based on 4 x 8 foot sheets. Occasionally I need to take a sheet of luan or regular plywood and cut lots of holes in it. I have created the silhouette of jungle vines and redwood forests. . . that sort of thing. Every now and again I need to make something large and yet it must be very light weight. So today I got to thinking about a product that would be very useful for me. Somebody has probably already invented it, I just need to find out where. . .

I want something that is like foamcore board. But instead of paper on each face, I want luan or some other lightweight (1/8") wood panel. In the middle I want something like styrofoam that is light and easy to cut with a jigsaw. This product must be without voids and be easy to paint. It must come in 4 x 8' sheets, be 3/4" thick and cost no more than $40.00 a sheet. I occurs to me that this miracle product would be great in teardrop construction. . .

So, DOES ANYBODY MAKE A COMPOSITE PANEL PRODUCT LIKE I AM DESCRIBING? And if so, how come we are not using this miracle product to make teardrop trailers?

If the product does not exist, I think somebody could make a fortune by developing it for theater applications. . .

[teardrop_focus]

I want something that is like foamcore board. But instead of paper on each face, I want luan or some other lightweight (1/8") wood panel. In the middle I want something like styrofoam that is light and easy to cut with a jigsaw. This product must be without voids and be easy to paint. It must come in 4 x 8' sheets, be 3/4" thick and cost no more than $40.00 a sheet.

So, DOES ANYBODY MAKE A COMPOSITE PANEL PRODUCT LIKE I AM DESCRIBING?

No, sir; not for $40 per sheet... about the only thing w/ a wood veneer that's as thin and lightweight as you'd like would be some uber-pricey aircraft interior panel$.

I work in the flim bidness (intentionally misspelled) and am intimately familiar w/ foamcore and luan... those two materials remain the two current standards for building (luan) and lighting (foamcore).

Consider, my good man, that since necessity is the mother of invention, this could be your first step towards financial independence...

[teardrop_focus]

Damn you, sir.



I wanted to build my teardrop w/ simple, traditional materials: (mild steel chassis), 3/4 ply floor and 1/2 ply walls, 1/8 ply ceiling...

Now you have me thinking of building my teardrop's walls w/ a solid panel (no stick framing) of bonded 1/8 veneer sandwiching foamcore... it would wind up being less than 5/8" thick, be somewhat better insulated and weigh practically nothing...

[halfpastsix]

Plastic Soffit...





It weighs nothing, is strong, waterproof, easy to cut and cheap. I don't know how good it would be for making theatre sets, but for a camper it's perfect. If I were to do it again, I would forget about the wood framing and just glue it together, it is that strong.

[aggie79]

I haven't used it, but our local plywood specialty company has Foamkore panels made by Kerfcore. They only stock 4' x 8' x 3/4" with hardboard faces, and it sells for $61/sheet. Kerfcore is available with poplar faces too.

Here is a link to the product:

http://www.kerfkore.com/NEW%20BROCHURES/foamkore.pdf

[Spadinator]

Plastic Soffit...





It weighs nothing, is strong, waterproof, easy to cut and cheap. I don't know how good it would be for making theatre sets, but for a camper it's perfect. If I were to do it again, I would forget about the wood framing and just glue it together, it is that strong.

How did you finish the edges on this. I have been thinking of using it for my new build.

[Grid Runner Adventures]

that sounds like what my camper is built out of. but I made the panels myself. laminated 1/8th inch ply to each side of 3/4 inch foil foam board.

check my website for pic's www.offgridrving.com

[halfpastsix]

How did you finish the edges on this. I have been thinking of using it for my new build.

I used plastic angle to start with. It is just glued on. You could use aluminium angle or anything really. To cover up my bad silicone work, I used plastic corner used for plastering.

[Spadinator]

Ok thanks.......

[bdosborn]

Make your own lightweight panels. Its simpler than you think:



Plastic from HD, packing tape, and a shop vac.
Bruce

[eamarquardt]

Make your own lightweight panels. Its simpler than you think:



Plastic from HD, packing tape, and a shop vac.
Bruce

I like it!!! Just shows that where there is a will, there is a way. All it takes is some imagination or some input from someone that knows more than you do!!

Cheers,

Gus

[Trackstriper]

I haven't used it, but our local plywood specialty company has Foamkore panels made by Kerfcore. They only stock 4' x 8' x 3/4" with hardboard faces, and it sells for $61/sheet. Kerfcore is available with poplar faces too.

Here is a link to the product:

http://www.kerfkore.com/NEW%20BROCHURES/foamkore.pdf

If it was readily available the FK75PP12 might be really nice...3/4" extruded polystyrene faced both sides with 1/8" poplar plywood....20# for a 4x8 sheet.

[Cliffmeister2000]

For your application, how about the plastic corregated sheets that I've seen real estate people make signs out of? Strong, light weight, and waterproof.

http://www.coroplast.com/

Note: The above linked website also mentions a new, expanded PVC board. That has an interesting sound to it...

http://www.foamboardsource.com/special- ... t-4mm.html

$485 for 25 sheets. At $19.40 each, luan is still far cheaper.

[Duane King]

I haven't used it, but our local plywood specialty company has Foamkore panels made by Kerfcore. They only stock 4' x 8' x 3/4" with hardboard faces, and it sells for $61/sheet. Kerfcore is available with poplar faces too.

Here is a link to the product:

http://www.kerfkore.com/NEW%20BROCHURES/foamkore.pdf

That Kerfcore certainly has promise. The product information on the web-site says that storage may be a problem. The panels have to be stored flat in a non-moisture environment. Our theater strorage buildings are very crude with not much climate control. So that may not work. . .

I like the homemade panels that Bruce did with the plastic sheeting and the shop vac. Pretty neat. What kind of glue did you use to laminate everything together, Bruce? Did the shop vac really keep everything flat while the glue dried?

[Ageless]

Duane; the concept about vacuum bagging is that you remove most of the air from the surface. That allows normal atmospheric pressure; about 7 lbs per sq.inch. to apply even pressure.