Reply by a1Jim

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Posted on Plywood Alternative

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#1 posted 06-29-2012 05:13 PM

You can use Paul’s Idea or mine they are both glued in the middle, depending on the span you have you could Incorporate Joe’s idea with a hole saw to take some of the weight out. Using the foam core all you do is spread some glue over either the foam or the 1/4” material (I’d use liquid nails) and do a bunch of figure 8s rather than solid glue and apply a reasonable amount of weight on top(belt sanders,routers,spare pieces of plywood) . The thickness of the foam will depend on what thickness you want and the span you’ll have. If you are going to drill holes in the bottom I’d wait for the glue to dry.

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