eamarquardt wrote:
Even better would be to separate the two 1/8" layers of ply with spars. This would result in an I-Beam like structure and would be both lightweight and strong. Hollow core doors are made this way and they are very stiff for their weight. Filling in the void with insulation would be easy and effective.
Hope this helps.
Cheers,
Gus
I have to agree with Gus When I built the little 4x7 I only used 2 laters of pebble grained FRP panel I installed the inner ceiling attaching it to the 2x2 spars that were 12" o/c. I went outside and installed 2 layers of 3/4 foam in the voids between the spars. I then taped the foam to the spars and overlapped the osb sides for waterproofing.

I installed the roof with rosettes sealed with 100% silicone

And the end product weighed in at 535 pounds ready to sleep !

Even tested to 10 degrees and a brisk wind it was 78 inside with a tiny ceramic heater

The chuckwagon was not insulated but recieved only the FRP roof attached again with rosettes

Yes that is 1/2 of a concrete block filled with cement holding down the tarp
( the hatch was not on yet)

The rack was off of a jeep and very easy to cut down and attaches AT the spars.
Here we are showing off for the CRA Gathering
