Trunk Sheet Metal

[SySt]

I have some large gaps in the hole of my trunk around the fuel cell I installed. I want to cover those holes up. What guage of sheet metal do you guys recommend? I was thinking 18Ga should be fine.

Any idea on how to help seal up gap between the fuel cell and it's mounting frame? Maybe i'll just use some sort of caulking for now as I don't see a reason to remove the cell anythime soon.

Here's a pic of what i'm talking about.

 

[Wiisass]

18 gauge should be fine. You could probably get away with thinner in the spots where the sheet metal would be better supported, otherwise it would warp. When I cut out the spare tire well, I had just temporarily riveted in a piece of 0.050 6061, it rattled, but there were no ill effects.

As for sealing around the fuel cell, I would find some kind of weather stripping or foam, I wouldn't use caulk, just seems messy and annoying if the fell has to come out.

What are you doing about a firewall?

 

[SySt]

Alright, 18Ga it is. I can always change it if something bothers me. As for the firewal, I am not doing anything at this time. Not like my car fits into a racing class that it can be competitive in anyhow. I do later plan on cutting out a lot of the unibody structure and "converting" to using tubing for structural parts. At that point the entire trunk will probably be walled off.

 

[Clip]

just a thought, after you rivet/weld your sheet metal in place in a few spots i'd go over it with some seam sealer from Napa. that way you'll retain a little flex and won't pop welds off if the thing happens to bend a bit.

 

[SySt]

I just had a thought. What if I covered the holes with 18Ga sheet metal like I was planning. However instead of using weather strip to seal the cell to the cell mounting frame, I built a box around just the cell about 3" high using 18Ga sheet metal as well? Of course the top of the box would have to be easily removeable for refueling. I could maybe use DZus fasteners to hold the top of the box. Would that be race legal? I think it would be from what I have read. I do still have the fuel line routed inside the car, I am definitly considering routing it outside of the car. The only problem with that it keeping the line away from the exhaust pipes.