I rarely get over here as I spend too much of my free time at Fine Homebuilding and Breaktime 3, but I think I have the best chance of finding a solution from the folks here at Fine Woodworking.
I need to make an ultra-flat panel: 4′-2″ x 6′-2″ x 1″ or 1.5″ thick, which will be supported horizontally along its two length sides. It will have a paint finish. Weight and structure is an issue, so if making it out of 1″ MDF, it will be too heavy and will eventually bow/ sag.
My solution:
A. Sandwich 1″ rigid insulation panels between 2 sheets of 1/4″ plywood or MDF, within a framework of 1″ plywood on edge, 16″ oc and at perimeter. If I bond 1/2″ x 1″ poplar to the plywood along the perimeter, I’ll have material to trim after fabrication to make it square. Bondo all exposed seams.
Assembly will be made using a vacuum press.
Thoughts? Go ahead. Start poking holes and making improvements.
Frankie
Replies
Torsion box.
What JC2 said.
Use two of these sandwiched between two 1/8 Masonite, they are the cheapest torsion boxes around.
Yes, a torsion is what's needed. Thought a scaled down version, using rigid insulation, might be a faster way of doing it and getting similar results. I was waaaay overthinking it and was lazy.
A torsion box it is. Thank you all for getting me back on track.
Frankie
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