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  • I know the answer is carbon fibre

    I think the answer is probably Aluminium. Your 2040×1000 sheet in 2mm 5-bar treadplate would be just over £150 delivered and 11kg

    The advantage over plastic is high elastic modulus and high strength, so you can use a much thinner sheet.

  • I'm not sure whether the price or weight is most disturbing, but my expectations of cheap plastic sheet were probably a tad optimistic. Smooth sheet is about £25 cheaper than treadplate though.

    More contemplation due.

    Ta.

  • More contemplation due

    You already have time and money sunk in the project. Do it right, do it once.

    Marine ply is cheap (<£50 for 12mm thick) and should last a couple of years with no maintenance. You'd need to do the maths on what thickness you need, 6mm is going to be roughly the same weight as 2mm aluminium.

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