What thickness ali sheet do i need for the chassis?
Im thinking 3mm for the floor and .8 for the bodywork. Is 3mm overkill or could i get away with 2mm?

steel floor mate .8 for the skin

Cheers. What thickness steel?

2mm for the floor and 1.2mm for the sides

i'm not a lover of ali floors, mines steel and seam welded, its not going anywhere. i wouldnt trust a rivited and bonded floor

if you have some bracing fitted for the seats then you could use ali for the floor. 3mm sounds fine, thats what I used for my side pods on the 7 and I could stand on them without denting, any thinner and they would have.

2.0mm ali mate,1@ 8x4 foot should cost you around £40 +vat
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2.0mm for the floor fixed/sealed with PU adhesive and 4mm rivets at 50mm spacing.

I used 1.50mm for the interior panels and battery tray etc. TBH 1.20mm would have been better for these panels as it's easier to cut and shape and lighter too. Fixed and sealed again with PU and 4mm rivets at 50mm spacing.

Hi 16g is fine for the floor. When was the last time you heard of an alloy floor coming of. Just use the right rivets and sealant.

Cheers Matt

0.022" stainless sheet riveted to floor. I used stainless so it wouldn't rust, since if it was regular steel, any paint would get blasted off by gravel and sand. I didn't use aluminum because I wanted better protection.

How thick you make it is completely up to you. Even 0.010" material is plenty for structural strength, the issue though is to prevent rocks or other road debris from coming through the floor. What you you think is the worse thing you'll ever run over is what will dictate what material and how thick to make it.

That said, doing it over again I'd probably use aluminum; stainless is nasty to work with - wear gloves!

[Edited on 4/24/08 by kb58]