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I think this discussion has gone places not completely relevant to whether or not the benchwork is sound. If you construct on an open grid or L-girder frame, and provide joists at 16" or so, I don't think the superior structural rigidity of plywood (as compared to foam) is really a factor over these distances.This really is an area that is somewhat scale specific, however. (At least where the larger scales are concerned.) I am a firm believer that for all but narrow shelf style layouts, the benchwork should be built robust enough to hold your own weight. Sooner or later you'll have to put your weight on it to do scenery, change light bulbs, etc. I also believe that a little common sense is in order here; 2x6 L-girders are, of course, absurd. If you're in doubt as to your carpentry or structural design abilities, there are plenty of published works available detailing construction techniques for adequate benchwork.I think that maybe we're not seeing the forest through the trees. Ever examine the construction of an aquarium stand? They're made of 1x lumber, usually Oak or Pine, but also even Particle Board. In addition, they're often only stapled together. Now seawater weighs 8-1/2 lbs/gal, so imagine what even a 50-gallon tank weighs with sand, gravel, rocks, etc.My point is that it's not necessarily the gauge, or even the structural integrity of the materials we use, but how we use them that counts when constructing a solid foundation.As to the use of foam:[quote user="orsonroy"]It's a sort of copout to use all this great foam base material roughed into almost the proper profile, and then slap on some plaster. Why not just save the time and expense that goes into the plaster and instead keep carving the foam until it's right?[/quote]Or... you could save the expense that goes into the foam...I can completely see where foam has disticent advantages when modeling flat areas and it's ease of achieving sub-track level terrain. I don't however see any advantage to using it to build up massive areas for hills, mountains, etc. (Except for tree planting.) It seems cost prohibitive, especially if you're going to go over it with plaster/sculptamold anyway. (Newspaper, cardboard strips, etc. are virtually free, why spend the money on foam...)About the only other consideration would be the noise...
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