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Considering 2' thick foamboard's ultra light weight coupled with the amount of ruggedness and strength I want, I'm considering using this material for a layout and I'm open to suggestions for the best material to use for its frame work. I need this layout to be as lightweight as practical since there will be occasions I'll have to move it and temporarily store it away. I'm 70 with rotator cuff shoulder issues and all such moving and lifting will be done solely by me without assistance from anyone else. So with that in mind,instead of lumber for the underlying support structure and legs, I'm considering using plastic downspout material for the horizontal framework. Being hollow plastic it's lightweight and I think it's rectangular shape and ribbed sides will provide adequate structural strength and the support needed for framework without the potential weight, flexing, and possible warping of wood. Also, used vertically for the table's legs, a downspout's end dimensions will provide a wide footprint base for the layout's stability.

Looking for opinions, suggestions, and feedback on my ideas. Thanks.

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 I resemble your maladies and empathize.

I have used 2x2 wood uprights, and "L" girders made from 1x2s and 1x3s. VERY light weight and strong. I wish I could remember the book I have (had ) about it. The entire book was about open grid layout tables or some such thing. I'll poke around, but am sure someone else will know it.

I recently needed a table to butcher a 300 lb. pig. I pulled out 4 2x2s and made 2 "L" girders as noted. One then adds  some lathing as cross supports and me and the pig had a great time. In fact I had some of him for breakfast today.

Lying rigid 2 inch foam on that should work. Consider how tall you want it for access.

Ernie

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