I'm just starting to sort out making a new engine cover for my 101 as the existing one annoys me and has big gaps all round it.
I have been trying to work out exactly what to make it out of.
I have some 1inch angle iron which i was going to weld and bolt into some sort of frame. Onto this i was going to mount some ally panels.
The whole thing is going to be easily and quickly removable for easy engine access (unlike the standard cover!)
However - what sort of thickness ally should i be thinking of using if i want to be able to stand on it and also want to be able to cut it up/work it easily?
The existing cover seems to be about 2mm. Is this a sensible sort of thickness to make something you want to stand on out of, or can i go thinner (like 1.2mm or so) - as this would be a lot easier to work as it can be cut with snips. I can always put more supports under it - or will it just deform lots the first time i stand on it even if i do this?
Looking at my landy, things like the doors only seem to be about 1-1.5 mm or so, and i know that i can stand on a flat landy door without it collapsing. Is normal ally the same sort of strength as landy ally though? I have been told and read that birmabright is stronger.
I have also been thinking about sound proofing. I have some sheets of plywood hanging about and was considering building them into a sort of 'outer skin' for the engine cover. Would they do much to deaden the noise, and would they take the heat without combusting or warping?
I will also buy some proper heat reflective sound proofing stuff to stick underneath the ally, but was just wondering if the ply was worth bothering with for even more peace and coolness.
Thanks