Light, Modular Sleeping Platform

Every sleeping platform I've seen has been built with plywood. I have some ideas on what I'd like to do and input concerning any aspect of my plans would be greatly appreciated!

I'm looking to make it as light as possible. Are there options other than plywood?

Reinforced Polyurethane Foam?
http://machinedesign.com/article/a-...do.kimble@paladintechworks.com&YM_MID=1323637

I've also wondered about some sort of basic metal support structure topped off with a thin plywood or type of laminate.

In terms of the design, my wife wants more headroom when possible but I'd like the option to raise it up when more gear needs stowed underneath. I'm thinking a 3 panel design with some sort of shelving support on the edges (perhaps using the rails to minimize plywood there too). The platform could be placed on the wheel well level support already built into the truck, or raised up to the top of the bed on a support system I will build.

I'd use 3 panels across the bed. Two cut so they could be rotated and dropped all the way to the floor longwise for instant carpet between the wheel wells when the platform is not needed. The remaining panel could then be a shelf or table positioned anywhere in the bed at one of two heights (or removed completely).

With the three panels, any could be lifted to access items under the sleeping platform (I don't plan on making hinged doors). I want it simple, light, and modular.

I'd rather not line the edge of the bed with plywood to make the upper supports (and storage/support along the sides doesn't work or I lose the ability to adjust the height). I'm thinking of a bracket connected to the rails that then supports the panels at the upper level (like a giant shelving bracket). Would the rail support this or would that be too much weight?

Any ideas and input would be much appreciated!

Thanks!

-Warren

 

Ever get anywhere with this? Interesting product.

 

Yes, I am very happy with how it turned out. Here is more info:

http://www.tacomaworld.com/forum/2nd-gen-tacomas/13598-show-me-your-shell-55.html#post5666251

I have a video of the final product that I need to edit and post to youtube that will help you get a better idea. It shows the install process and gives more info about the materials. I've been dragging my feet getting it done. I'll try and get moving on that one again....

 

I'm curious about what thickness you used and how strong it ended up being vs. plywood. Looks like you're using center supports. Also what was your source of the reinforced foam?

 

Yes, I decided that going with inch and a half (what you'd need to avoid center supports) was just too heavy. Especially since I wanted to easily remove and reinstall it. I didn't want a center support but in the end, didn't see another way to do it. So I went with 3/4 inch plywood and an adjustable center support.

I bought 2 sheets of 3/4 inch plywood and the support lattice was left over from an old Ikea bed frame.

The low position is supported only by the built in side rails on the truck and my center support on the jack stands. In the high position, I add the cross beams (more for keeping the center support centered than providing actual support) and two side rails to get the height up.

On the bottom of the plywood planks (the bed), I put a couple of small blocks to hug the middle support and keep it centered in the low position (so I didn't have to use cross beams and cut off another half inch of clearance to slide in my gear). The high position isn't as stable so I still use the cross beams and it is rock solid (but there is enough height there that it's not such a big deal).

Those adjustable jack stands were really tough to find, I looked everywhere for the perfect thing.

http://www.amazon.com/gp/product/B00...ls_o03_s00_i00

I added a memory foam mattress topper and it works like a charm! Nice and warm too, even when it is snowing and cold out! When it's hot, I just pop open the screened windows.

Another added benefit of the bed is when storing everything underneath, I feel my gear is a little more secure than had it been in the back. I keep the top clear except for a sleeping bag and it looks empty so I'm not so nervous heading out on hikes and whatnot. My tailgate locks and it wouldn't be a quick break a window, grab my stuff, and run off because it would take some work to get underneath the bed.