upper rear bunk matirials

[Borden]

The upper rear bunk on our boler is very very heavy. drop down face could hurt someone if they were not carful. Span is just over 6' long. Need ideas for material to replace it with. Fixed part is original, has no back, 3" tall rail on window side for stiffness, piano hinged to face side. The face has been replaced with a very heavy material; no doors now. Would replace both with lighter material. May not add doors back, just make it look original.

Considering laminating 8' 3/4" thick pine boards to needed width as that would be lighter not sure it would work at that length. Plywood types vary in weight but do not know what products would work. Online found a honey cone sandwich much like a hollow door that would work, but is not sold or shipped to Canada.

Would help gain back some of the extra weight added by other repairs. What have others done?

Any ideas would be considered. The upper bunk is needed for a grandchild bed.

[tractors1]

For strong but lighter weight than solid wood try Baltic Birch plywood. Usually found in 5 or 7 layers; much lighter than even pine. Many big box stores carry it.

[Jon in AZ]

I like the idea of cutting radiused openings without doors for storage access when folded up and to reduce mass. Perhaps reinforce the front edge with aluminum C-channel?

[FRED SMAILES]

How much weight will the bunk need to handle?

[Borden]

Originally Posted by FRED SMAILES

How much weight will the bunk need to handle?

Grand child, about 60lbs so far

[Borden]

Originally Posted by tractors1

For strong but lighter weight than solid wood try Baltic Birch plywood. Usually found in 5 or 7 layers; much lighter than even pine. Many big box stores carry it.

Will look for this thanks