ᐅ Reduce the weight of a wooden box to make it easier to carry on the back.

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ello everyone,

I have a somewhat unusual question.
I built a wooden box measuring 60cm (24 inches) long x 60cm (24 inches) wide x 100cm (39 inches) high, weighing around 30 kg (66 lbs).
The box is meant for a specific costume and, essentially, is worn on the back as part of the costume.
30 kg (66 lbs) is still manageable in terms of weight, but my problem is that for the costume to be complete, a person needs to fit inside this box.
That brings the total to around 85 kg (187 lbs), which is quite heavy.

My next step is to reduce the box size by about 25%, and the intended person still fits inside.
My question is what else I can do to make the box lighter.
I considered making the "lid" and side panels out of foam, but I’m worried that it might not support the weight if someone is sitting inside.
Does anyone in this forum have any ideas or suggestions on this topic?

So the box should be lighter… then you will need to make it smaller and/or build it from a different material. Maybe from sheet metal—can you weld?

Or you could change your character. Make them 80 years old, then the box would pass as a shopping trolley on wheels ;-)

Wouldn’t a bag work just as well?

(Side) panels made from aluminum sheets (available at any hardware store – tread plates or similar) and covered with plywood or, even better, wood-grain adhesive foil.

Benutzer200 schrieb:

(Side) panels made of aluminum sheets (available at any hardware store – tread plate or similar) and glued with plywood or even better covered with wood decor foil.

Using aluminum/sheet metal is a good idea, but the problem is that in the locations where this box is used, aluminum/sheet metal etc. is not allowed.

Possible (but expensive) would be a construction made from fiberglass-reinforced plastic panels / fiberglass mats. You can use your current wooden box as a mold for this.
It’s similar to how you might build a canoe.

Stable, lightweight, no problem with metal detectors (stadium?).

You might consider leaving out the side panels and instead use jute straps as connectors. I mean something like wide shutter tape.
It sounds like you’re making a medieval costume. You can definitely rely on traditional materials for that. They are very durable but unfortunately difficult to find because they are considered old-fashioned. 🙁

If the lid and base are connected, you can still cover the sides later with a thin board or stretch fabric over them. That way, everything will be opaque.