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Has anyone heard of "luane?"
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<p>The key here is the quality of the plywood - not the thickness. Most plywood will warp over time if not attached to a strong frame - like 2x4's in household construction. Higher quality plywood is made to not warp in frameless construction such as cabinets.</p><p>The 1/4" plywood with a luan skin is also a more stable sheet good to be used in places where warping cannot be tolerated. It has minimal structural strength but will not warp on its own if reasonably supported.</p><p>My overall suggestion for a layout that must be:</p><ol><li>Lightweight</li><li>Moveable (frequently)</li><li>Durable</li></ol><p>2" foam + 1/4" high quality (luan) plywood + 1x2 framing.</p><p>Total thickness = 3 3/4 inches.</p><p>Build the frame on a level surface. Be sure to glue the 1x2 framing together. Glue the plywood to the frame. Glue the foam board to the plywood. Be sure to do all these steps in the same session before any of the glue has had time to fully cure and harden.</p><p>Make sure the plywood is fully adhered to the foam board. That is, a full surface coating between the two surfaces - not just a few wiggles of glue. You can get a small can of flooring mastics that is safe for foam. A mastic that is "water cleanup" is usually safe for foam. Use a notched trowel or putty knife to spread the mastic evenly over all the surface of the plywood. You can buy plastic notched putty knife and throw it away once done.</p><p>Join the plywood and the foam together on a level surface; weight it down evenly and allow to dry overnight.</p><p>Use 1/8" masonite or 1/4" plywood for a 3 3/4" fascia all around the layout. Make sure this fascia is also fully glued to the frame. This will add additional structural strength to resist warping and racking.</p><p>Good luck,<br />-John</p>
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