[ratdude747]

This may get the 2011 bizzare idea award, but ive wondered if one could use corrugated 2-ply or 3-ply cardboard, similar to what appliance boxes are made from.

cheap, easy to obtain, light, and eco-friendly! also easy to work with if you have a good, sharp utility knife.

again, fender washers reccomended. also for heavy things, you would want to use some sort of back support to add support.

another thing i have seen used is 2" grid plastic, like used as florescent light diffuser panels.the 1" stuff is too weak, as in 2009 on 1747, I learned that it was a poor material for electronics mounting (sags). the thicker 2" grid works, as i have seen teams like 461 use it in the past. to mount things, you use zip ties to loop around the gridwork.