Ultralight Floor

[levsmith]

Since you do not have a rear hatch, you don't have to worry about a bulkhead.

My floor has both a 2x2 perimeter frame with 2x2 and 1x2 xmbrs (all light weight select cedar) that are infilled with 1-1/2 thk blue foam, then sandwiched between 5 mm (3/16 inch) thick 5 ply Okoume marine ply.

Plenty strong enough. I wouldn't want to dance on it, but I can crawl and lay on it, and once the mattress is in, spreading the load, it will be fine. During construction, I have a piece of 1/2 inch ply laid down on top so I can walk on it having to think about it.

It is not the lightest, but due to the size, I had seams in the skins that I wanted to back up with xmbrs, and I have attached my walls to the floor using screws, so I wanted the beef of the 2x's.

I'm a believer in the foam core for its insulation value, both thermal and acoustic.

For your much smaller footprint, and reinforced glass construction, I would think that you could use very little wood, maybe just some anti-crush blocks where you will bolt thru the trailer frame mounting features. If you are glassing the bottom I don't no why you would need a full bottom skin. Maybe a thin 1/8 inch ply on top before glass, just to minimize how much epoxy and glass is needed to get the penetration resistance up (plywood being less expensive and lighter than epoxy and glass... I'm guessing).

thank you very much! This will help a bunch

[angib]

Sorry if I came off as a know-it-all with my comment as that was not my intent.

And let me say that I was not suggesting that! It's just the phrase 'torsion box' is like a red rag to a bull where I'm concerned....

[KCStudly]

Maybe it would be better described as a "two flanged diaphragm beam", but it doesn't quite roll off the tongue the same way.

[kayakdlk]

I built my 5'x10' floor out of 1"x3" laid flat with 1/8" plywood on top and bottom (1" total thickness), with spars across about every 30" to align with my frame. I placed 3/4" foam in the voids and use PL premium to glue it all together. I covered the bottom with a layer of 12oz fiberglass cloth and 2 coats epoxy, the rolled on a coat of black duplicolor bedliner paint. For the top I used 2 coats epoxy and then varnished it. It was plenty strong to lay on and I even stood/kneeled on it several time with any fear of breaking. The foam in the middle firms up the panel real nice.

Dan

[levsmith]

I built my 5'x10' floor out of 1"x3" laid flat with 1/8" plywood on top and bottom (1" total thickness), with spars across about every 30" to align with my frame. I placed 3/4" foam in the voids and use PL premium to glue it all together. I covered the bottom with a layer of 12oz fiberglass cloth and 2 coats epoxy, the rolled on a coat of black duplicolor bedliner paint. For the top I used 2 coats epoxy and then varnished it. It was plenty strong to lay on and I even stood/kneeled on it several time with any fear of breaking. The foam in the middle firms up the panel real nice.

Dan

Thanks Dan! I'll have to check out your build thread!

[RogHodge]

I think it can be done. The tires wheels axle are the heavy bits.
I was almost standing on my roof and thought two things,
Wow this is strong!
And
what the heck are you doing up here, get down!

[GPW]

I still think we need to do some experimenting with common gray chipboard as a skin ... Available in many thicknesses ...easily waterproofed... sticks to foam like crazy (actually dries inside very quickly ) ... and very Strong ..
Thinking a foam floor with basic framing on the edges and blocking for the attachments , all covered by a thicker 0.125” chipboard top and bottom , then painted ... bet that would be Strong and light ... No chance of de-lamination as with the dreaded plywood ... The thinner plywoods we usually have readily available are the Worst quality for what we want to do ... Unless you spend the BIG bucks .... Which I think most of us are trying to avoid ...

[lthomas987]

Tonight at Menard's (a bigbox competitor) I found a whole roll of the paper chipboardhttp://www.menards.com/main/paint/drop-cloths-plastic-sheeting/drop-cloths/paper/builder-board-temporary-flooring-protection/p-1735545-c-8061.htm. It was being sold as floor covering for use during construction. 38 inches wide, and 50 ft long. It was on sale for $29.78. I didn't pick it up. But it looked and felt exactly like the backer board of a legal pad.

[GPW]

I worry about this part ... "Repels water, mud, paint and more”

[mdk]

I worry about this part ... "Repels water, mud, paint and more”

What is " Liquid Shield technology " anyway?

[mdk]

Then there's this:

http://www.whitecap.com/shop/wc/54803

[KCStudly]

Both sound like heavy versions of rosin paper which will repel a little water (before turning to mush). Anything sold as a floor protector is likely to have some water repelling additive (maybe wax?).

Stick with packaging of art supply.

[wagondude]

We have a box manufacturing factory here. They also have a warehouse that does product packaging and distribution. They also have a warehouse where they allow the public to come in and buy stock size boxes, sheet corrugated and packing materials. I would almost bet they would also have large sheets of chipboard (stock to bake back cards for blister packs). Check for local box/packaging manufacturers. They tend to be regional businesses as shipping empty boxes can be expensive.

[mdk]

Both sound like heavy versions of rosin paper which will repel a little water (before turning to mush). Anything sold as a floor protector is likely to have some water repelling additive (maybe wax?).

Stick with packaging of art supply.

The one I linked says it is "Strong and tear resistant chemically inert polypropylene". Nothing in the other one says squat about being polyethylene. It is brown, and looks like paper, but that's not much of an image.

[KCStudly]

Hmm, I missed that.