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flysar's avatar
flysar
Explorer
Jul 17, 2013

91' Hallmark Bed Sag Fix

I removed the 1/8" luan top piece of my bed area expecting to find severe dry rot causing the center of the bed to sag on my recently purchased 91' Hallmark Cuchara.

I was surprised to see no wood rot but the sagging center supports were only 1x2's over a span of 54" with 24" between each board.

I have a Kreg Jig system so I can easily glue & screw new supports like what is there but would expect them to eventually sag again.

- I could epoxy & screw some 3/4 x 1 x 1/8 aluminum angle along the 2 center boards reducing the chance of sag

or

- Put more center boards in, maybe 4?

or

- Install 2x2's in the center & add another 1x2 on the edge boards to match center boards height

What makes sense and will best minimize sag?

I'm 205 and would be the primary user with my wife joining me occasionally.

  • What you're trying to make is called a "torsion box". The skin must be rigidly attached to the frame tying it together as one structure.

    Think of an "I" beam: the I shape (would be handy if this font had serifs on the I) is really about the two horizontal surfaces held together at a distance apart by the web. If you support both ends of a beam and add a load to the span, the beam tries to bend under the load. That means the top horizontal surface is in compression - it's trying to get shorter; and the bottom horizontal surface is in tension - it's being stretched. The further apart those two surfaces are, the stronger. The separation of the horizontal flanges influences strength more than their size - this is whey a 2x4 is stiffer on edge than laying flat.
    The center of the web has no load at all on it - you'll sometimes even see I beams with large holes in the web to reduce material and therefor weight/ cost.

    Ok, so for a TC cabover, you want the web as tall as possible, and you want the skin (plywood) glued/ screwed to the frame rigidly. Even foam insulation board in this scenario - if continuously attached to a skin on each side - adds significant structural strength. That's why airplanes, boats, etc. are often made of a tough, strong skin (carbon fiber) sandwiching some lightweight honeycomb material. It's an I beam in sheet form... like the floor of a TC cabover.

    I worked the math out for a platform bed span I made years ago: Click for math.
    I was frustrated by very seasoned pro woodworkers not really having any idea how to CALCULATE or ENGINEER the structure... they all just guessed and used their intuition, recommending a structure which would have been a LOT heavier and more expensive to make. From the date on that blog post, I can tell you that bed platform has been in service for 5 years now, no problems.