Have been working on my trailer (this one: https://luxurylandyacht.wordpress.com/) and it's coming along GREAT. Now that it's warmer out I'm getting back in the swing of things and starting to thing about interior finishings.
The general plan is that there will be a pair of benches up against the sidewalls in the rear of the trailer, and one bench/cabinet containing a pull-out kitchen drawer thing in the front of the trailer. All of these need to be covered with some kind of removable panels. In addition, there are going to be removable panels between everything to convert the whole thing into a bed. All the benches (the frames) are going to be welded out of aluminum angle and square tube.
Have been thinking about how to make all these panels and hopefully keep everything lightweight - trying to keep the final product under 1000# hopefully for towing with my little car.
My first thought was just to use nice 1/2" plywood, but I'm worried on the wider spans (~26") that it might get kinda bendy without lots of (weight) reinforcement. That would work fine, but if I can save 20 or 30 lbs by using something lighter I'd rather do that.
Second thought was to try making some plywood-foam-plywood composite panels and see if those are strong enough. I was thinking maybe 3/4" foam & 1/8 plywood skins. Has anyone ever made anything like that or anything to solve a similar problem? I have all the equipment I need to make it happen (a nice vacuum bagging system namely), and I'll probably go ahead and do some experiments, but if anyone has already done the science I'd be happy to ride their coat tails.
There are a bunch of similar commerical products, but most of them are too thick/heavy/hard-to-source to be of practical use to me.