My recommendation would be 18-20 guage and then use a bead roller or a punch and flare tool to add rigidity to the panel.
A flat sheet will be flimsy and you would need a thick heavy piece to add any structure. Most common bead rollers and punch/flare tools are only good to 20-18ga anyways. 16ga could be used if your bead roller will do it. Either way you'll need to add some structure to the panel for rigidity.
Yes, where the trap door would be. I don't have a trap door, just a panel bolted in place, so a rear fire wall wouldn't interfere with anything. I have an Eastwood bead roller that I've never used, so this would be a good starter project.
For looks, or protection? For looks, you'll be fine. If for protection- not so much. I've seen firsthand what happens when a Mustang gas tank ruptures in a rear end collision. The '67 coupe was pretty well smoked from the dash rearward as the gas sloshed into the cabin area and fire destroyed everything! If you protect the trap door area, you've still left the area over the wheel wells unprotected and fuel can slosh up into them. You might also consider the Tank Armor plate that tops the fuel tank- assuming that's what you're after...
Point taken. If you select the highest rated 2016 vehicle and it's rear ended by a semi trailer tractor that's going 80 mph, you stopped on the highway changing a tire. Can you make this safe for the stopped car?
I'm also planning on covering the wheel well area, I may do the over the tank area, but want to get the rear firewall made first. The wheel well areas may be difficult with all the curves, etc.
Is this the same mod in the old Boss 302 manual? the whole sheet welded to the structure behind the rear seat?i think it states .060 sheet in the manual.
If I was going to try and protect myself from the possibility of a fuel tank rupture in an early Mustang this is probably what I'd do....
a. Cut the top off a standard replacement Mustang fuel tank, place it in the trunk OVER the trunk floor sides and perimeter weld it place.
b. Make an enclosure to seal the filler neck from the passenger compartment and also weld in place.
c. Weld in attachment points fore and aft underneath for fuel tank straps.
d. Place a new tank in from underneath and attach with straps.
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