In a message dated 1/22/2010 5:05:31 A.M. Eastern Standard Time,  
[email protected] writes:

Yes,  that's foam core. I did some ballistic tests and found that as
long as it  was in sections no longer than about a foot, it was
paintball proof  although close range shots do tend to dimple a little.
It stands up to  blunt impacts very well. What it can't cope with is
punctures and any  sharp, pointy impact goes through it like a sharp
thing through foam core.  On the other hand, I knocked up the whole
body in less than a day -  including scaling and drawing - and a hot
glue gun, a sharp knife and a  cutting board are all that is required
to make repairs. All box sections of  the body are filled with
expanding foam for additional strength and the  chassis is built from
channel section aluminium. Total cost of the body was  less than £5 so
if it fails miserably I can always make a new one in  plywood. The
really major advantage of foam core as a none-structural  material is
that it weighs sod all. I would guess that a similar body made  in ply
would weigh four or five times as much.


what if rather than using plywood for the body itself, use a piece of  
sheet metal? it would stand up to hits, be fairly strong (and with the  bends 
for the body shape it should be more rigid and possibly remove the body as  
one hole piece giving you plenty of access to anything inside), but should 
weigh  less (or be about the same?) than a plywood body
 
Chris,
_Odyssey  Slipways_ (http://hometown.aol.com/odysseyslipways/index.html) 

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