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Old 04-01-2008, 02:14 PM   #1 (permalink)
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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.

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Old 04-01-2008, 02:45 PM   #2 (permalink)
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I would also like to know as I am looking at the same. Thanks.
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Old 04-01-2008, 08:09 PM   #4 (permalink)
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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.
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Old 04-01-2008, 08:32 PM   #5 (permalink)
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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



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Old 04-01-2008, 09:18 PM   #6 (permalink)
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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

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Old 04-01-2008, 11:19 PM   #7 (permalink)
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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.
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Old 04-02-2008, 01:11 AM   #8 (permalink)
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What about carbon monoxide being trapped between the belly pan and the car? Potentially poisonous.
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Old 04-02-2008, 01:37 AM   #9 (permalink)
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Quote:
Originally Posted by Otto View Post
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.
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Old 04-02-2008, 09:02 AM   #10 (permalink)
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Quote:
Originally Posted by Otto View Post
What about carbon monoxide being trapped between the belly pan and the car? Potentially poisonous.
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.

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