Rigid foam cabinets?

[junglejim83]

Take a look at Kerdi-board by schluter systems. They make all sorts of closed cell foam for bathroom tiling applications. I imagine the foam insulation is cheaper and for certain applications just as good. Anyhow, looking at how the kerdi is used gives some interesting ideas for use in a complete gut job, where stick-built cabinetry is being replaced.

The thicker kerdi board can be used for making benches in showers which means it should support a lot of weight and I don't see why you couldn't use that or 2" closed cell foam to make ultra-light dinette benches and platforms.

I think the only caveat on using it for cabinet doors is that you might need to use piano style hinges or make sure there is substantial reinforcement backing where the hinges attach.

I bet you could keep a Compact JR w/ an all foam interior under 1000 lbs.

[tractors1]

The Kerdi description states it's extruded polystyrene (XPS) as we've been discussing but with a trademarked name.

[junglejim83]

I wasn't sure if the core material was much different if at all. I remember kerdi being expensive, but it does come pre-backed w/ fabric providing the tensile strength (and I think tape that can be used in the corners), so it might help minimize the screening step.

As a fellow DIYer, I would probably opt for the method shown in the video because of the cost. But the time savings might be worth it to others. Anyhow, cool thread.

[Gerry]

Mark you hit it all right on the head. As a construction and boat builder the fiberglass skin is where it's all at.

[Jim Bennett]

Originally Posted by junglejim83

Take a look at Kerdi-board by schluter systems. They make all sorts of closed cell foam for bathroom tiling applications. I imagine the foam insulation is cheaper and for certain applications just as good. Anyhow, looking at how the kerdi is used gives some interesting ideas for use in a complete gut job, where stick-built cabinetry is being replaced.

The thicker kerdi board can be used for making benches in showers which means it should support a lot of weight and I don't see why you couldn't use that or 2" closed cell foam to make ultra-light dinette benches and platforms.

I think the only caveat on using it for cabinet doors is that you might need to use piano style hinges or make sure there is substantial reinforcement backing where the hinges attach.

I bet you could keep a Compact JR w/ an all foam interior under 1000 lbs.

I have used Shluter Kerdi 100's of times in the past, including the Kerdi Board. Great stuff for tiling.

Though even a bit more expensive than Kerdi, we have now been using wedi Building Panels for tiling. It has an XPS core, and has a thin layer of fibreglass on each side. It is even more rigid than the Kerdi, and the joints are much easier to do using a strong, waterproof caulk/adhesive. This product would work will for cabinets.

The big drawback of either of these systems, or the system described in the original post's video, is their toughness. Sure, they are strong and light, but they can be damaged easily. A knife cuts them fairly easily, and any sharp object would penetrate the surface with minimal effort. To combat this, you could put a layer of thin plywood on places where this type of damage might occur.

Using a fibreglass with resin combination for the skin would give a much stronger surface, which would better resist damage, as it could be built up more in areas more exposed to being damaged.