Plywood alternatives

[2014 Warthog]

I'm thinking about a drawer/sleeping system. I would LOVE to keep the weight of the thing as low as possible so I was considering some sort of plywood alternative.

Has anyone here worked with things like Bluewater 20 or 3M Reinforced Polyurethane Foam or anything like these?

Expensive but with weight savings of up to 50%, seems worth it. Worried about being able to use screws on it or anchor tie-downs etc. No experience of the actual strength.

Any comments appreciated, thanks.

 

[FactoryRide]

Check out Goose Gear. Saw them the other day, and their stuff seems pretty sweet. Aluminum frames. Supposedly lightweight.

They're kinda pricey.

Goose-Gear - Home

 

[BlackWorksInc]

Why not go with an Aluminium frame/sheet box? You should be able to make it lighter than say a plywood box and have it be as structurally sound?

Not entirely sure I'd feel comfortable with foam, and the fiberglass reinforced stuff I feel would be better to use as panels on an aluminum frame'd box than anything too load bearing.

 

[mxer]

80/20 strut would be the lightest/strongest IMO with plastic paneling but quite pricey as the strut is about 4/ft.

McMaster-Carr