Freelancer:
hotkinkstersforu
Solution to all your problems
You've got a great idea, but it is too complex. Simplifying it will solve most, if not all of the issues you've had. Instead of the design that you started with, use a telescopic, collapsible tube/ U channel like a slide children use at a park. It can readily be sturdy, yet fairly inexpensively made using a variety of suitable materials, shaped easily, store in a compact manner (think the vintage telescoping cups), and has no hinges. Add pieces that fold down as the supports to hold it off the ground and you're in business.
