Devon pop top upper bed super strength

[Aberdeenbus]

Hi,

I'm wanting to re make the upper bed for my side opening Devon roof so that 2 adults can use it.
I'm thinking 180 kg ish

So it's 1200mm wide with a 30mm lip, I was thinking of a series of crossmembers from aluminium rectangle box 40x20mm with 3mm wall thickness every 300mm sandwiched between 2 skins of 3 or 4 mm ply.

Strong enough ?

Anyone with experience of making something similar?

Cheers
Si

[discipleofsketch]

I was thinking about something like this the other day - mine has the original boards, very strong - will sleep two adults no problem, but very, very heavy solid chipboard.

I want to put my van on a diet and was thinking of making something hollow with crossmembers.

[Aberdeenbus]

Yep lightweight is the next concern after load capacity, the aluminium won't be that cheap.
If I know it will be rigid enough I guess it will be worth it.

Si

[petethefeet]

We have the original boards still in ours, they appear to have a wood frame about 30mm deep and then a sheet of hardboard on both sides,in the middle I think is a honeycomb to space them apart. One board creaks abit as I think the glue may have gone in the middle. I think a similar construction is used on the cheap flat sided internal doors. Hope that helps

[hakuna matata]

We have the original boards still in ours, they appear to have a wood frame about 30mm deep and then a sheet of hardboard on both sides,in the middle I think is a honeycomb to space them apart. One board creaks abit as I think the glue may have gone in the middle. I think a similar construction is used on the cheap flat sided internal doors. Hope that helps

Ive got two of them bed boards for sale here . was going you usse them on mine ,but did not and they are sat in my carport ,need the space .

neil.

[Aberdeenbus]

Cheers for that however I can get 50x25mm aluminium box section 3 mm wall all I need to make up the two sections I want for about £35.

So I'll give it a go n if it works post some pictures.

Cheers

Si

[a1winchester]

Steel is 3 times stiffer than ali and generally a good bit stronger. It won't suffer from fatigue from all that flexing (ooer!)

OK it rusts, but pre-galvanized should be ok.

Just a thought...

[Aberdeenbus]

Hi,
A wide range of materials we considered as weight is a key issue, one of the best things about being up here is all the specialist engineering firms and a couple of vehicle body builders.

I even got a guy offering to price it in carbon fibre lol.

Ally was chosen over steel as it's almost three times lighter

Cheers
Si