Possible frame design idea

[FettFanatic]

Well it has come time for me to finally get to work on my HIC. I have had a Stormrider full front panel laying on the floor for well over a year now.

The problem I have been trying to come up with a solution for is weight. I have been trying to come up with ideas on how to make a lightweight box that is also accurate in dimensions and details. I want to be able to take this to troops and other events without having to get out the forklift. I think I have come up with an idea that may work, but I wanted to run it by some others first.

I was thinking of building the box out of blue/pink foam board and then coating it in fiberglass. I would build up several layers of the foam board making the trapezoid shape and roundovers on the top. I would aslso make a slight recess in the top to inset the front panel in. Before putting the panel in I would coat the entire front and sides with a fiberglass shell. Do you think this would work? I don't know if the fiberglass will stick to the foam board or not. I guess the insets into the sides for the panels would act a little like keys to hold everything together, or I could put a fiberglass layer on the underside as well to hold it all together.

Just throwing out ideas.

 

[Mike M.]

maybe try making it out of 6mm sintra? a 4'x8' sheet of 6mm thick weights 28lbs and it might only take two to build the box.

 

[dlzx9r]

Sheetmetal sounds heavy but not that bad. It's going to take a couple of folks to move it any way u go. My finished HIC is around 150 pds.
If your building it to move around alot make the side panels removeble. My first time moving mine was bad. I went back and added magnets to them. I remove them before I even think about moving it now.

 

[FettFanatic]

saint nasty - Do you think the sintra would flex? I would be afraid that sitting it up on its end would cause the sintra to bend, but I have never used sintra so I don't know how tough it is.

dlzx9r - Yeah I was thinking of using magnets on the side panels so they could be taken off if needed or if I decide to upgrade at a later date. I had seen yours was made of sheetmetal. I might go that route if I had the metal working skills, but I don't.

If I go the route I was talking about I think I have decided that the back will really need to be fiberglassed to ensure strength and stability.

 

[Mike M.]

6mm should have the rigidity you need, especially if you built a good frame for it.

 

[Fett 4 Real]

You know sintra is pretty sturdy.....Hmmmmmmm Id goto a sign shop see what it feels like...if you box it smf possibly make the bottom area open but boxed in maybe a rectangle with a rounded off rectangle inside the bottom maybe add some hand holds on the bottom as well...hmmmm this has me thinking

 

[Huntman]

sintra seems like a nice light idea

 

[FettFanatic]

I like the idea, but getting the round overs would be tricky and it would still need a frame to mount to I would think.

 

[gymbeau2000]

I made my box out of foamboard. Was cheap and easy to make..and super light. Problem occurred when the wind caught the HIC during an outdoor event. KNocked it over and a corner broke. I can fix it, but the box is much lighter than the front panel....so I want to upgrade to wood. Just remember, when you paint it, use a brush on primer, then spray paint it. The spray paint eats the foam. I used the Stainless Steel spraypaint....the stuff that's suppose to have metal in it. It comes out like a gunmetal color and matched the HIC from SR perfectly. No panels though....