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Unread 06-10-2016, 14:26
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Re: Q. Best sheet metal design?

Thinner 5052, used in better shapes and bent such that the geometry of the part provides the structural support you need. .090 5052 is pretty commonly used and works well. My team used .125" this year because of the rough game (and the lack of other things to take that weight up), but generally .090 is preferred.

If you're having problems with strength, deflection under load, etc. it's most likely a design problem and not inherent to the material. Sheet metal is harder to get right than tubing based designs.

If you / your brother have some specific examples / photos of where this material has let you down in the past, I can try and provide half-decent design advice for working out the bugs in the future.
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