My pads coming together. Might be a bit heavy! I think I over did the density thing. But I can always replace with lesser dense foam. Sondor (check their web site) is the place to go for close cell foam. The EVA (Expanded Vinyl Asetate) is the foam to use. It has a memory and will retain its shape. It comes in different densities. 30kg/m3 to 250kg/m3. I used the 60kg/m3 but would maybe reconsider the 30kg/m3 (Used for gym mats). In between the 25mm EVA close cell foam I sandwich the 50mm chip foam (Open cell). This makes for 100mm of fully shock absorbent material. When you compress the EVA it feels soft, but once pressure is applied over and area it really absorbs the load. In hind site I would have bought softer inner open cell foam (mattress) to make the landing more comfortable. The EVA takes out all the nasty rock impact, whiles the softer foam allows for absorbing your body weight!
Now the External hard wearing protective layer. Canvas/Nylon/Cordura!!!! I settled with a Nylon outer casing (Also called Cordura) It took some shopping around, but I eventually found it! Not the thickness of my Franklin Climbing Pad but almost there. It is being stitched together at the moment and hopefully next Wednesday I should have a triple pad of hybrid design. It will concertina like the mad rock triple pad. 3 off 600mm by 1000mm pads giving a total area of 1,8mx1m.
The price =\\- R1, 800 bucks! So if you’re not up to it or not an engineer like me definitely rather by one. I recon I will save R1000 bucks on a triple pad, but as it is an trial and error exercise, it might end up to be more expensive!
Anyway for all you guys out their trying their own thing hope this helps. If you need more info or some fotos let me know! O yes any comments or suggestions let them flow.