Where to get materials for Undercarriage cover?
 

I just went around looking for aluminum sheets to cover my undercarriage for my car and a sheet of .22ga x 10ft x 4ft piece of sheet metal is around 70 bucks.

I was thinking plastic sheets would be cheaper, just as light, and just as durable as aluminum. Where does everybody get the materials they get for their undercarriage covers?

The cheapest source for corrugated plastic (coroplast) is harvesting campaign signs after election day. It's a bit late for that this year, but you can buy sheets from sign shops. Some people have also had success finding them at home improvement stores like Home Depot. Prices seem to vary, but people have reported in the $20 range for a 4' by 8' sheet.

Actually, I just looked online. I feel dumb. Found a 4' x 8' sheet of ABS plastic for 27 bucks. Pretty cheap if ya ask me for something that is that strong. :) Going to use that for the majority of it and then sheet aluminum for the hot areas. :)

Where'd ya find the abs on line?
Watch out for shipping costs if not buying locally.

I'm partial to 2.7 mm. lauan plywood from your local big box home improvement place. Prime with oil base house paint and use big washers with any fasteners so they don't tear through.

Not for high heat areas though. Duh.

check this out.

I asked the manager of all the local branches of a convenience store chain if they could hold the coroplast advertisement signs for me instead of throwing them away, he said sure. reusing and reducing waste feels good. go ask, worst they can say is no, right?

My whole thing with modding my car is to not use really cheap looking thing and not degrade the looks of the car. I'm trying to make a compromise of looks and performance additions. I'm working on the front right now with a plexiglass front to to increase aerodynamics and do the whole grill block and what not. It will also be easily removeable with a few wing nuts. Duct tape and that chloroplast plastic stuff doesn't seam that durable.

mcmaster.com carries an extremely wide variety of plastics.

However, if you want to save a good deal of money check your local phone book or use google maps to find a nearby Plastics Shop.

I tend to buy 30 pounds of scrap plastic for $30 once a year from Piedmont Plastics.
They have many locations in the Eastern US: http://www.piedmontplastics.com/locations.asp

I personally would recommend using polycarbonate. It can handle a much wider temperature range and will be able to handle more abuse. 1/16" or 1/32" thickness will work fine. If you want it opaque black you can recolor it with automotive interior spray paint (which is actually vinyl dye).

I'm very interested in what you come up with, the wife's jetta3 is bugging her with fuel consumption, so I will likely be starting to mod it. this is DEFINATELY a subject (aesthetics and well builtness, non-duct tape special) that you and I will agree with, or, well, you and her. I mentioned grill block and she thought it would be hideous, so I'll have to come up with some pretty nice looking peices if they make it on the car for normal us.
now MY car is another story, testing with duct tape and coroplast or using them in reasonable locations is just fine with me, as long as it works