Quote:
Originally Posted by johnlvs2run
Please elaborate about the sheet metal flashing. HD has a 14"x25' roll, and I wonder if it would be suitable for a nose on the bumper.
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I don't recall the gauge, and the sticker on it is long gone. The one I got was a 50-foot roll 20" wide and cost $50 (I would have gotten the ten-foot roll, but that was $40 at the time, go figure). Probably more now as it was over four years ago.
It's galvanized steel flashing, and (at the gauge I have, anyway) it can be pretty sturdy with relatively simple construction. For instance, there's no reinforcement behind the airdam, it's just a skirt of the flashing, with the bottom edge folded under and another, flat sheet cut to shape and pop-riveted to it. I can push on the bottom edge of the airdam and rock the car back and forth while it's in park (on a level concrete garage floor, anyway) without any noteworthy deflection. Then again, I do have 35 sheet metal screws securing the airdam to the bumper...
You might get away with just using the sheet metal and pop rivets for creating an extended nose on the car, as long as any flat areas weren't big. For reinforcement I recommend aluminum, 1/4" x 3/4" seems to work well for flat bars (that you can bend to the desired shape). The sheet metal screws I have work well in this size bar. Aluminum L-bar is good for supporting flat sheets, like the undertray under the engine bay (though I wish I'd used one size larger than what I did, it flexes a bit more than I'd like).
I hope that answers your question, please ask again for any specifics you were looking for that I missed.