A pair of Ntrak modules with plaster scenery require 3 men to lift and stack. I'd say, by the effort expended, they must weigh half a ton. But a single HCD is 25% less square feet. And no box. So it will feel like 600 pounds. ;-Þ
I have no idea what mine weighs, but it's close to 60# or so, 36x80". Mine's all mountains, and the legs and a plywood base (to extend the 30" wide door) all add to it. It's still lighter than the last one!
BikerDad built me N-trak modules here in Vegas using the 2" blue foam. You'd have to ask him how/where he got it from. But I know it is available in Vegas...seems everything is, just got to find it.
This isn't just a weight thing. Foam is freekin' expensive... a 4x8 sheet of 2" insulation runs about $35 at Lowe's / Home Repo in the Outer Main Line area. For added security I'd recommend filling those air pockets with sprayable foam ("great stuff")... it expands and hardens nicely.
There is really no need for great stuff. Again, I'm not sure about the rest of you but I don't plan on standing on the layout. Too many people over build their layouts. The HD foam is a lot stronger than most people think. Besides, the "great stuff" is very dangerous to work with in this situation. It can expand enough that it could blow apart the mountain. I have tried it for terrain before and it is just too spongey when cured and impossible to predict how much it is going to expand. As far as the expense, 2 2" sheets which would be enough to do most 4x8 layouts with a decent amount of landsacaping is still cheaper than wood and plaster required to do a cookie cutter / hardshell style layout. Have you priced good plywood recently? Not OSB or exterior sheeting but decent, warp free plywood.
Oh I completely agree. Foam always wins over hardshell. I'm a pretty big guy and I tend to lean on the layout surface, so overengineering in my case makes sense.
