Quote:
Originally Posted by botsapper
Try:
PVC closed-cell boards (Sintra, Celtec,etc) - Inexpensive, lightweight, fire-resistant and very easy fabrication techniques.
Thermoplastic acrylic-polyvinyl chloride alloy sheet (Kydex) - Very tough and abrasion, chemical & fire resistant. Very easy to work with.
Low Weight Reinforced Thermoplastics (LWRT) - Lightweight plastic composites with low thermal expansion and good mechanical and high impact properties.
High-density polyethylene (HDPE -cutting boards) - High impact properties and low coefficient of friction. Already used as auto & truck underbody splash shields & skid plates.
General purpose ABS sheets - High impact & strength properties, Easy to work with and a common auto trim material.
Good luck on your material choices.
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Botsapper, what is the relative costs of these materials.
I would mention a couple of other materials. One, coroplast, has seen wide use, is inexpensive, lightweight and does come from sign companies in 4x8 sheets. It has good weather resistance and can be cut with common boxcutters. Several folks have placed it a couple of inches from exhaust pipes/mufflers without ill effects.
Perhaps the most versatile approach of all is foam/fiberglass sandwich that was used by 3-Wheeler in fabrication of his Insight boattail. The beauty of the approach is that it is almost infinitely flexible as to how various bulges and odd shapes are accomodated. The down side is that the approach is very manual labor intensive. Take a look at the consolidated link here:
http://ecomodder.com/forum/showthrea...ect-13533.html
Keep us updated on your progress.