My layout is to be 2 foot by 4 foot with a possible extension added at one point. Since the layout is completely flat, I am seeking something light weight, but rigid enough to attach items to its edge. The best I have come up with so far is two sheets of 2 foot by 2 foot by 3/4 inch balsa core board. I would then dowel and glue the two pieces together to make one 2 foot by 4 foot by 3/4 inch board that is hopefully lighter than plywood but with good area to attach to. This layout will not have a permanent home and that's why I would like it light. I would also like to find a solid 2 x 4 piece, but any of the balsa I have found seem to have expensive shipping hence attaching the two 2 x 2s. Any thoughts on other materials or just other ways to go about this would be greatly appreciated. Jim
I agree that balsa is light, but I don’t know how strong it is. I always thought it was soft (or is that basswood?) so just be careful not to get big dents in it. It splits pretty easy along the grain, so be careful with track nails around the edge of the piece if you use nails.
If you added glueing 1" rigid foam insulation it would further stiffen and provide additional strength at the joint. I'm using 1" foam and 1/4" plywood which is nice and stiff, but I guess not worth buying a whole sheet...
Don't big box home hardware stores sell 2x4 plywood hunks? I've certainly seen them here. Top it with foam. Or, what about a HCD? Buy this and saw off one end: https://www.homedepot.com/p/Steves-...ite-Interior-Door-Slab-J62H1FADLC99/204609477 Since you are going to be "portable", you might consider mounting a pair of handles on the flip side for easier handling. Four of the squarish ones would be nice and will double as tiny "legs" and be very stable.
That would be my solution too, laminating 1/4 Inch ply to 1" rigid insulation. Neither component is expensive and the result would be very light. Home Depot's website shows precut 2' x 4' x 1/4" ply at just over $11 Ea. Jim, if you were to build on the foam side, you'd be able to excavate the foam in places for a nifty creek and a railroad bridge.
Thanks for the ideas. Since I do not want any varied terrain, the idea of the 1/4 inch plywood seemed best for me. I have two other small layouts with highly varied terrain so this one is to be a dead flat yard primarily to perform operations. Since 1/4 inch plywood lacks inherent straightness, I plan to reinforce the plywood with two 1/2 x 2 boards running the length of the plywood. At one point I would like to be able to attach a one or two track wide extension about a foot or so long. I have not done any modular work so I'm not sure of the best way to attach this to the 1/4 plywood.
That should work. If you use 1/2 X 2 all the way around the perimeter of both the main part and the extension, you could bolt them together.
