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Gary.... A couple of thoughts/questions on the warping plywood. Did you use a water-based glue? Was an entire sheet of ply (i.e. 2x4 or whatever your module size is) laminated to the same size piece of foam? Was there any cross bracing, or braces at 90 degrees to the ply? I have seen an interesting drawing that shows a foam layer laminated to a layer of doorskin, but the doorskin has big holes cut in the middle (sort of like steel structural bracing). Then there are 3" strips glued at right angles to provide rigidity (is that a word?). The author alszo recommended using panel adhesive, which is not water-based. However, having said all that, we currently build our modules to the standard that www.railwaybob.com describes, using either dimensional pine or 3/4" cabinet grade ply ripped to nominal 1x4 or 1x5. We do not have any problems with sagging or flexing on any modules built like that. Andrew
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