Folded sheet metal would be good. The thing is that making a sheet
steel (or aluminium) body would cost a lot more in materials and even
more in tooling. Foam core is dead easy to work with.

On Jan 22, 3:46 pm, [email protected] wrote:
> 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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