Bellypan materials
 

Time to talk about bellypan materials. Obviously coroplast is number one and will make up most of the pan. But, we must deal with exhaust in certain areas. Aluminum seems to be a good alternative. Its very light weight, durable, and resists corrosion very well. However, its not the cheapest... I know some guy still use it though. Where do you get your aluminum from? What else can we use around the exhaust piping and components?

Edit: Just did some searching around and it seems aluminum flashing is actually pretty cheap. Yay.

I would also like to know as I am looking at the same. Thanks.

How about these:

http://www.metalsupermarkets.com/
http://www.onesourcemetal.com/index.html
http://www.metricmetal.com/index.htm
http://www.brindleymetals.co.uk/
http://www.americandouglasmetals.com...abrication.htm
http://www.mskent.com/
http://www.aaluminum.com/anodized_al...t_for-sale.asp

And Sheet Metal Info Sites:
http://www.sheetmetaljournal.com/
http://northstar-metal.com/NSen.html...FQnNIgodr03IYA
http://www.alibre.com/promos/online/...FQ58PAodkzLgKQ

Robert

I know I saw someone here do a coroplast bellypan with aluminum flashing over the exhaust tunnel, seems like the way to go.

OTOH, my coroplast on my (partial) front bellypan isn't looking too shabby for being a mere 1-1.5" away from the exhaust header. I'm beginning to think the whole exhaust heat thing is overblown.

But then again, my car's cat converter is right under the header. I'm sure if your cat is under the car you'll won't want coroplast anywhere near it.

I used aluminum coil. This is the same stuff, but you can get it at home depot. Just ask for vinyl siding aluminum coil. The down side is that it transmits noise.

http://cgi.ebay.com/White-Aluminum-C...QQcmdZViewItem



http://i75.photobucket.com/albums/i3...n/IMG_2383.jpg

i go to the places that buy scrape, most have piles of mixed sizes that they will sell by the pound. Have a good idea of what you'll accept. because there are so many different thicknesses. Take a tape and a micrometer along. And a design in your head. Angles and tubing round and square are very useful. For the light stuff i buy the rolls of roof flashing from home depot etc. Also make your angles and square tubing out of the lighter guages. If they are paying $0.50 for flat mixed, then you'll probably have to pay $0.75 or $1.00/lb. Make sure you get a receipt because the stuff could be "hot". With the high prices, there is a lot out there. Happy Hunting

side skirts hinged for lift arm access. both skirts were made from a road sign the county scraped.

lovemysan, I saw pics of yours, i think on GS, that underbody looks great. Are those vents down the middle and on the right? Rear wheel skirts and underbody are next on my list.

What about carbon monoxide being trapped between the belly pan and the car? Potentially poisonous.

I think that there are plenty of little gaps to prevent CO from becoming much of a concern, elpecially with an "enthusiast" designed bellypan.

With an OEM bellypan I'd be a bit more concerned. I'm sure the fit and finish would be a bit tighter, but look at the Lotus Elise bellypan (there's a thread and everything.) It has NACA ducts in it, no CO buildup there.

I pretty sure that my car doesn't produce carbon monoxide. Maybe carbon dioxide. As for it getting to the cabin, the floor of the car has no holes or access points. Any gas would have to travel from the trunk area through the rear seat area. The saturn is reasonably air tight, the only time I get air that smells of exhaust is when I drive with the trunk open.

When I had my undertray, I ran coro on the front, sides & rear, AL flashing over the exhaust. I did a cutout in the coro in the front section around the catalytic converter, about 1.5 inches gap. Same observation as Andrew: not a problem, no adverse heat effects.

"Belly pan off" was the "B" state of an A-B test (http://forum.ecomodder.com/showthread.php?t=79 ).

Honestly, I was disheartened by the results, and so not super motivated to reinstall it. Also, winter came. And went. And came again.

I still have all the pieces. It'll be going back on.

Do you have more pictures of that bellypan? What did you use to attach it? It looks very professional.

there is a link to pics in my sig. Its attached to an aluminum frame. The frame is screwed to the car using self tapping screws.

Excellent thanks! I've been looking for a cheap source of thin gauge aluminum for ages.

EDIT:
Is the aluminum sheet also attached to the frame with self taping screws? It almost looks like rivits from the pics but I'm not sure. Thats one of the best solutions I've ever seen.

EDIT 2:
Did you see an appreciable gain in fuel economy with the extra air dam over the belly pan alone or were those 2 separate setups at different times?
thanks

From those who have done belly pans, and wheel skirts on rear (& front) - I would like to ask for some Instructors, Assistants, Volunteers, or Helpers for my little event on April 10, 2011 - The First electricfly Event - "Electricfly Aero Mods" - Fuel Economy, Hypermiling, EcoModding News and Forum - EcoModder.com - Just a quick little idea recently put together to have a little gathering on a sunday afternoon!

Belly Pan Fit & Finish, and Flat & Trueness thoughts
 

I think we all need access to a Z-Corp Hand Scanner type of device, so as to make a support structure that realy is flat - no matter if we use cloroplast, aluminum, or vinyl skins on our pan! It would allow modeling the actual underside of the car, and allow for structure to be designed to fit the actual car's high and low points but still give a straight line flat for the pan!

Scanner Video - in action!.

When used with a 3D Printer - we could get some very fine fitting results worked up, and even make pans and supports for sale to other ecomodders, even if just the scan files or CAD files were made available!

It would be nice to have an EcoModder Group Display - if not at this years EV Fest - then for Next years show! Aero Caps, Belly Pans, EV Conversions, Boat Tails, Front Skirts and Air Damns - to name a few exhibit ideas!