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Hello All,

I am building a mobile cart for a marching band, that will hold various pieces of electronic equipment - including a synthesizer on the top. It's going to be fairly big, and I want to keep the overall weight down as best I can. I've attached a drawing that will give you an idea of the rear of the cart, where the musician will stand while playing an 88-key keyboard that will sit on the top, left side.

The rack mounted equipment (right side) will utilize rack rails such as these: Racks and Cabinets - Wall Mount Racks - Vertical Rack Rails - NavePoint .

I'm wondering if the carcass of this beast can be built out of structural insulated panels (SIPs) to keep the weight down. I'd make them myself by sandwiching 1/2" foam insulation panels between 1/4" sanded ply and 1/4" or 3/8" OSB, with the strongest construction adhesive I can find.

Thoughts / other ideas are greatly appreciated and thanks in advance.

BG
 

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I'm wondering if the carcass of this beast can be built out of structural insulated panels (SIPs) to keep the weight down. I'd make them myself by sandwiching 1/2" foam insulation panels between 1/4" sanded ply and 1/4" or 3/8" OSB, with the strongest construction adhesive I can find.
By the time you sandwich a 1/2" foam panel between two 1/4" sheets, you may as well just egg crate it with 3/4" inside. A torsion box sorta.
You will want structure all the way around for attachment.
I'd look into aluminum extrusions which will give more strength and resistance to road shock.
Like this:

The weight will be supported on the wheels so that minimizes the effort.
The wheels should be semi-pneumatic, not solid and as large as possible to reduce rolling resistance.
Consider 18" bicycle wheels. I have an old 3 wheel child stroller and it practically rolls on it's own accord.

Mount all the electronics on shock absorbing cushions rather than attaching directly to the structure.
It should have a waterproof cover that's flips up easily in the event of a storm.
Or a hood that covers ,most of the keyboard. Experienced keyboard players don't need to see all of the keys!
Will there be a need to read sheet music? If so, how will that be secured and still be viisible?
 
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One time use? I suppose the cart will be towed by a vehicle, (4 wheeler?). Why not build the carcass onto a 12' single axle (decorated, curtain draped?) trailer? ..... similar to a small parade float.

Sonny
 
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