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For materials,
I will probably build the frame as a tubular structure. I was thinking Metal conduit or PVC piping? For anyone with PVC experience, do you think it would be strong enough to support the weight? This seems easier since I can use a heat gun and bend it to the right shape.
I want to build the frame and then cover it in foam. After sanding/filing the foam, I want to fiberglass it with probably two layers of 4 oz cloth. Does this sound reasonable?
For the rear section, I will probably use 10mm coroplast that I have lying around.
Please give suggestions and point out problems if you can
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I think PVC is to flimsy. It is also heavy and would be hard to attach. A 10' stick of 1/2" EMT weighs around 2.2 lbs. is rigid and can be bent easily, but will have to be welded.
A big plus for using 1/2" builders foam is that one side has aluminum foil and the other side a plastic film. The aluminum foil side will keep the fiberglass resin from making contact with the foam and melting it.
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