Quote:
Originally Posted by freebeard
I'll never find the original thread, but someone who races dirt-track modifieds recommended an aluminum/plastic laminate that they use for those big wings they run. I did bookmark a source of the material, Polymetal. It comes in 1/8' and 1/4' thickness, with strength approx. equal to 5/8" plywood. A supplier local to me can provide it for $104 for a 4'x8' sheet: Sign Panels | NUDO®
The farther the better. Flush-headed rivets? 
You could put the bottom contour at ~10° and extend a flap all the way to the back of the gas tank/spare tire well or whatever's under there.
What do you plan to do to keep the taillights visible? |
Hmm Polymetal. Never heard of it, but coropolast under aluminum had crossed my mind, primarily for vibration damping but also a little benefit in buckling stength, although in principle it makes sense as a possible weight reduction method for the flat panel sections. I kind of think that a bead roller is still the best way to go in that regard, but probably I need to play with it, anwyways I haven't decided for sure I want to invest in a bead roller. But I might sell the SGII I won for EM's BD as justification for it.
Aerodynamically I think rivet heads don't matter, but I might have to flush them just for aesthetics.
For taillights, a trailer light set is the way to go. If I do a gapfill on the sides it will be clear plastic so as not to obstruct the stock headlights when the hitch box is off.