Ikamper RTT honeycomb floor delaminating and sagging

[casioqv]

I still have the very first kickstarter skycamp that I have recently upgraded to basically a brand new DLX tent as much as possible with the 3.0 canvas, 2.0 ladder, RTT Comfort air mattress, 2.0 brackets, light strips, window poles, etc. I love the modularity and upgradability of Ikamper designs. However, the fold out honeycomb panel has started to delaminate internally and bends a lot when someone climbs inside- usually dipping about 2", and I am worried it will buckle and hurt someone.

Does anyone have ideas on how to repair this? IKamper said they won't sell me a replacement fold out floor, and I can't find anyone having these issues elsewhere.

Some possible ideas I had:

1. Make a replacement floor section with plywood and epoxy- possibly also laminating aluminum flashing on the outside to make it look the same as the factory one
2. Try separating the aluminum skins from the internal honeycomb, and see if I can epoxy the layers back together
3. Bolt some support 'beams' to the bottom to support the floor- possibly using lightweight aluminum square beams (this sounds easiest....)

 

[Fenderfour]

I've used Coosa board as a good plywood alternative. it's expensive, but really great stuff. about the same strength as plywood, but much lighter and won't absorb water or rot. The major downside is that it doesn't hold wood screws very well. Most screw-in fasteners will need to be t-nuts. It can usually be found at local boat shops as it's frequently used to replace old wood transoms.