Modular Layout Construction

You can use PVC for legs with threaded couplings for height adjustment. I don't know about 1/4" plywood. I would recommend 5 ply 1/2" minimum. The plies are thinner, but it's a stronger material. Use cabinet grade if possible, it is better quality. Does anyone recommend LUAN plywood, I find it to have better resistance to moisture.

Don

1/2 inch birch is going to increase the weight. You can actually use 1/4" luan for the decks if you support it sufficiently.

Think about how tough a guitar is. The wood is less than 1/4" thick, but the face and back are supported by the curved edges. With a module, constructing it with cross supports braced properly by 1/4" sides with 1/2" ends (need stiff, straight ends for clamping and alignment) should yield a pretty lightweight module. You can top the luan with Homasote or 2" foam. Just don't drive screws into the luan or you'll get noise transmission. The down side is that you have to do more measuring, cutting, and gluing to put a module together.

There's a group called the Sippin' and Switchin Society and their modules are entirely luan with small corner bracing at the joints between the braces and the siding.

Here's an example:

Here's how the Sippin' and Switchin' group does a module. This one is a "simple" straight module, but they have curved modules of 8-foot radius (16-foot diameter) that are strong but light. All it takes is time, a good table saw (a miter saw would help), measuring, and patience. Hope this helps.

Thank you for your the input.  I have not seen Sippin' and Switchin Society before.  

I built 17 tables using 1/2 plywood framed by 1x4s and using mostly 2x4 for legs.  In some cases I used 2x2s or 2x3s for legs.  All plywood is screwed into the frames using drywall screws.  The legs are connected to the frames using hex bolts (2 per leg).

Matt, thanks for the pix of the luan modules.  I have used luan in the past but it was to make a couple of kayaks!  Bet ya' them suckers are really light!  Russ