I started to model the anti-intrusion plates. I still have 2 more to go, but this is a good representation of the challenge ahead. I would be able to cut them out on a cnc plasma. I modeled the top/forward one with 3 separate bends of 12 degrees to make the curve with the tubes. I doubt the 7075 would even bend that much. I could make that one out of 6061, I suppose. Here's what I will have to do:

-transfer the 3D model to 2D vector files for the plasma machine
-cut the panels out
-make bends in the 2 panels that will need them
-somehow clamp each panel in place, one by one, so I can position mounting tabs to be welded on the tubes (not modeling those...)
-finish-weld the tabs
-position, mark and drill mounting holes in the panels for the tabs

That's a lot of work. I guess the fear that's motivating me is of the fiberglass shattering/splintering and sticking through the frame tubes in a side impact. I don't know how likely that is, though. Plus, due to all the various angles and bends in the tubes, I will end up with a 1/16 to 1/8 gap between all the anti-intrusion panels and the tubes. Hard to say how much that will compromise their effectiveness.

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