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Support spacing for foam
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We built a 16' x 9' layout on 2' insulation foamboard using 1" x 3" pine boards around the perimeter and as joists spaced every 4'. We coated all of the tops of the pine boards with Elmers carpenter glue and placed the 2' x 4' foam panels on them. We sealed the seams on both sides of the panels with 2" wide, clear, packing tape. Legs for the table were made of 2" x 2" poles, drilled to accept 1/2" blinds nuts and bolts in the feet. The bolts allowed us to move the layout and re-level it easily. The legs were braced with 1" x 2" boards. <br /> <br />As we added additional pieces of foamboard to the surface of the layout for mountians, inclines, and such, we used carpenters glue as the adhesive. This technique added to the structural integrity of the layout. <br /> <br />Since we had no plywood underlayment, we could pearce the foamboard easily to insert track and switch machine wiring. We also found that wires could be secured to the bottom of the layout with a short piece of 2" wide packing tape. This method of securing wiring allowed us to add or move wires easily. <br /> <br />We had no problems with big guys leaning on the layout. The layout was solid, light, and held up well for the five years we had it on public display. <br /> <br />In my humble opinion, some of you guys might be over engineering the project. For doubters, I would suggest a simple test. Build a 4' x 4' box using 1" x 3" pine boards and glue 2" foamboard to the top of it. Stand on it, crawl on it, kmeel on it, and beat it up. You may be surprised how strong it is.
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