We built an entire car body out of foam and then covered both sides with fiberglass and polyester resin. EXTREAMLY strong. I weigh 175 lbs and can stand on the front end with no cracking etc. The reason for the strength is due to covering both sides. Think about a steel I-Beam. The reason that is so strong is because steel is hard to stretch or compress. It bends easily but not so easy to stretch/compress. The I-Beam forces the outside lays to stretch and compress in order to bend the beam in two. Having foam covered in fiberglass (both sides) is like making a continuous I-Beam through out your body. Want to have some fun? Make a sample and see how hard it is to break.
Here is our car body. Don't laugh, we are not autobody engineers and autobody technicians
![Smile](/forum/images/smilies/smile.gif)
Just an electrical engineer looking for something different to do.
http://picasaweb.google.com/stinger3wheel/Stinger