[svenw]

We have decided to look into changing our method of building from extrusion, to a welded/ riveted box frame, with a bellypan keeping everything together. The only problem is that we do not have the capabilities to machine a full sized aluminum belly pan. We are however getting a techno router installed by january, on which we are able to machine composites, plastics and woods. Does anyone have experience with the belly pan design and the strength needed for the bottom plate? Ive been looking at peek and noryl with 30% glass, as these are the strongest plastics that i have found. If we go with 1/4 " thickness and pocket it it similar to what other teams have done (1323, 254), would we see about the same strength for the same weight (peek is about 1/2 the density of aluminum)? We are completely new to this method of manufacturing, and are unsure how much force the belly pan actually sees. The only problem is that peek is fairly expensive, are there any cheaper alternatives that would also be strong enough?

thanks Sven