The 2'x6' recently built NOSS modules used 3/8" poplar for sides, 5/4 poplar 
for ends, 1/4" luan ply dadoed into the sides and ends for subroadbed and a 
couple of poplar 1x2's for stiffeners glued to the underside of the ply.  If my 
memory is correct they came in at 10 or 11 lbs before we added the 1/2 Homasote 
roadbed which essentially doubled the weight.  All wood and 10lbs at 2x6 feet 
seemed pretty reasonable to me.  The lesson learned involved the Homasote.  
That stuff is really heavy.  We just glued a 2x6 foot sheet on top.  If i was 
going to save weight I would cookie cutter the plywood and Homasote or use 
another lighter roadbed product to begin with.

I would look to Gator Foam or Polyiso insulation board for ultra light modules 
(say 5lbs at 2'x6'.)  The stuff is structurally stiff enough you could use it 
to build up your entire module.  I would skip any wood product altogether and 
clad the outside faces of the module with something like paper chipboard or mat 
board.  It's lighter then any wood product and would reasonably resist bumps 
and dents.

Chris Borgmeyer


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