In my quest to build a light somewhat portable (layout to workbench and back really) modular layout, I'm considering using 2" blue styrofoam sheet on a grid of 1"x1" timber (or maybe 1x2 sideways so height = 1"). The foam seems more rigid than either plywood or medium density fibreboard (MDF), so the question is, how often should it be supported to stop it sagging / twisting / warping? The shelf I'm targeting is only 14-16" wide, and very solidly built, and I figure on using 24-36" long modules for "man-portable" status. </font> Do I need any interior framing at all, or is a box-frame 36" long and 16" wide rigid enough?</font> Support every 18"? every 12"?</font> Given the high price of blue foam down here, I'm loath to make any (expensive) mistakes this early on.
What about using that 1' by 1' RHS steel tubing that comes with the aluminum angle peices,90*,45*,three way,four way etc etc corner peices etc.Just make a simple frame to fit around the outside of the foam base & maybe contact cement?liquid nails? Have seen it done in one of the MR mags some time ago.
i would build a frame of 1x4's, then on the inside attach 1x2's one inch from the top. laminate the foam to 1/4" luan and set this in the box. the foam would be 1/4" above the frame that can be tapered down to the edge. you will have room under the luan for wires, clamps, etc. hope this helps. david lived in NZ 1962-1965
