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Re: Plastics
Plastic for a bellypan is a bad idea. It isn't very rigid. I know that our bellypan is really important in our drive performance and would not work if it was plastic. However, I've heard that garolite is also a good Al replacement for bellypans too and is quite light, however it is difficult to machine.
We really like using polycarb. We use mostly 1/16" and a bit of 1/8". It waterjets fine and if you get smoked polycarb it looks great. We also usually bend it if we need a bit of rigidity. Bended polycarb makes a great replacement for AL as it can be really rigid, yet is light.
How thin al are you using?(Specifically on for the bellypan. Is the bellypan pocketed?) If you have some good sheetmetal capabilities using thinner aluminum(.06 and .09) could possibly be your best bet.
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