Aluminum skid plate build

I purchased a RAT Products 1/8" steel skid plate from this site, and it works well. Last fall I hit a rock on the trail and put a good dent in the cold rolled steel with no damage to my rig.

Issues with the RAT skid: it's heavy and hard to get on and off; it doesn't mate easily and elegantly to my Relentless aluminum plate front bumper; the side panels make it difficult to clean, installed, at the car wash. So I decided to build an aluminum version.

Design parameters:

Shape similar to RAT skid
Keyhole under engine mounts
1/4" aluminum to reduce weight
Fitted to my aftermarket bumper
No side panels to allow easier cleaning at the car wash
No oil drain opening (nice in theory but messy in practice)

RAT skid on the bench, design in progress:

 

My approach is to build an MDF version, get the tweaks worked out, then start cutting metal.

 

Layout is always fun.

 

Where do I get my curves from? Whatever is handy.

 

After cutting and shaping the MDF, I taped the fours panels together and installed the floppy unit on the rig.

 

Now I have all the angles of the new skid. I just have to save them on the template. Hot glue and scraps did the trick.

 

The MDF version completed.

 

One of the things I like about aluminum is that you can cut it with woodworking equipment, which I have. I use beeswax for lubrication.

 

Aluminum pieces after shaping. Some cleaning and they are ready to tack together.

 

I used a bevel gauge and tacked carefully to make sure I preserved the shape of the MDF unit.

 

After a few beads I could test the fit.

 

Then back to the welding table for lotsa beads. A final fit before paint.

 

You are quite the craftsman I can see. Nice tools. How much do you think you will save in weight? Will this provide you the protection as the steel one did during your last hit?

 

Thank you.

RAT unit is 39 lbs; my version is 26 lbs.

I hope so.

 

Sweet, it does look very nice. Like to see pictures when bolted in place.

 

Paint in progress. Should get a final installed picture up in a few days.

 

Very Cool. Is that an extra set you cut out? Can I have it?

 

looks good, dont you love how much noise it makes cutting alu on a table saw? also nice table saw setup.
on my last one i did that needed a bend, to cut down on welding, i did a releafe cut on the backside which allowed me to bend by hand(ish) then weld up that seam.