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

Created on: 4 May 2022 17:04
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DerKistenmann
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Large dark wooden cabinet on casters in the room, handle on the side, metal fittings visible.
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?

Large wooden box made of planks with dark tape, standing in the room by the window.
Tolentino4 May 2022 18:33
There is just so much out there. It’s kind of creepy. I’d rather not give any advice here.

Ah, I can't help it.

With Wedi boards (Jackoboard and similar), you might actually be able to keep the structure quite large and instead use thicker panels, then reinforce them not only with adhesive but also with long screws for added stability.
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Benutzer200
4 May 2022 18:36
DerKistenmann schrieb:

The idea with aluminum/sheet metal is good, but the problem is that in the locations where this box is used, aluminum/sheet metal, etc. is not allowed.
If you cover it with a 2mm (0.08 inch) wood panel, it won’t be noticeable. "Natural" materials won’t help you anyway.
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DerKistenmann
4 May 2022 18:51
I can guarantee you that everything happens on a voluntary basis for a partner costume.

I have also considered Wedi panels before, but I was told they would never hold up if I used them as side walls.
Tolentino4 May 2022 18:53
They are available in thicknesses of at least 5cm (2 inches). At that thickness, they can support my weight of 86 kg (190 lbs) — I even believe they can hold up at 3cm (1.2 inches).
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DerKistenmann
4 May 2022 18:58
Paulownia wood was also suggested to me, but unfortunately, I am not familiar with its stability.