Consider using Monocoque construction

[Bdubz]

Iam considering a teardrop build using 1" aluminum/honeycomb/aluminum sheeting as a monocoque constructed teardrop, whearas I can utilize aluminum angle for roof, flooring and side wall ties without having to make a elaborate frame skeleton from wood or anything else, monocoque style. I have used the stuff extensively when Ive built or modified aircraft and areospace components. It is extremely tough, and holds tons of weight, it is by default insulated too, and is used as structural bulkhead and flooring panels etc.... It surely would make a super lightweight teardrop. any thoughts?

[dales133]

Its done quite frequently down here in australia.
The only issue depending on where you live it has verry little insulation value

[noseoil]

No problem if you have access to the pins & epoxy, along with the experience needed to make it all work.

The problem I have with it is the cost, it was just too expensive compared to regular wood panel construction for me to consider for my build. We used it in aircraft cabinets & I agree with you, it's plenty strong & light weight, much better than anything else you can use for structural panels, bulkheads & interior furnishings. No reason not to use it, but cost would be a negative unless it's "free" for you to use.

[dmdc411]

I've considered this, but cost and availability is the reason. I too worked as a a&p until NWA layed many, many of us off (%! $$$&*!!!) Another story, but I have thought of aluminum square tubing and angle clips as ties and then .040 skin. It would be strong and fairly lite. Use 1/4" luan for the inside, fill all wall, floor and cling with 1" foam.

[rowerwet]

As a 20+ yr A&P I had the same idea, other than looking cool it will have no advantages over a foamie.
Metal is cold and noisy, even honeycomb materials.
Wood is cheaper, but rots.
Foam is naturally insulating, quiet, lightweight and rot proof.
Just look at the performance Rutan squeezed out of foam cored aircraft. 200 kts with low fuel burn from the same engine found in a Cessna 172