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You could get a sheet of 5'x12' 6mm ACM, cut it in half, adhere the two halves with the thin VHB tape and/or silicone, and cut it to shape. That would give you almost a ½" of material which would eliminate the need for any stiffeners/supports.
I'm going to order a couple of different sizes of these. Great idea for a work bench or "sawhorse" that easily collapses for storage or transport.
"The Centipede"
For flat-on-flat, Weld-On 3. You can simply lay the hanger bar on the face and using an applicator, the Weld-On 3 will flow between the two pieces nicely ("capillary"). It's nice stuff and extremely strong.
For uneven surfaces, the Weld-On 16 works really well. The attached photos show an...
This is what I received from GRS (I purchased the Secure Set SP):
Secure Set is packaged in 4 different case sizes. There are 1, 2, 3, and 4 gallon kits. Secure Set is priced at $28.00 per gallon plus shipping. As an example, one gallon of Secure Set (1/2 gallon of "A" and 1/2 gallon of "B")...
I have a bunch but so far have only used it to set the post for my mailbox. It wiggles more than concrete but it's also not going anywhere. You can set your post them pour the foam, but you can't move it afterward.
The issues I have are you can't move the posts around to level or plumb...
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