Back bumper gap fill?

I have ordered another exhaust tunnel cover from Stoke (which I'm picking up at ADI), which should cover things in the short term.


In the longer term, I'm still trying to find a practical alternative to that horrible looking correx. How about 1.5mm Polypropylene sheet (with an aluminium heatshield backing)? It can be heat-formed & drilled, described as 'virtually indestructible'.

http://www.theplasticpeople.co.uk/black-polypropylene-sheets-p-63.html
http://en.wikipedia.org/wiki/Polypropylene


At 1.5mm thickness it will need to be supported quite a bit, possibly using those plastic expanding connectors that Audi uses for the undertray (but what would they connect into? Something along the lines of the riv-nuts which Hotstuff used, expoxied into place?). I don't want to use bolts for the reasons mentioned earlier in the thread. Any suggestions would be welcome. The end result needs to look OEM (or at least, OEM as possible).
 
Is it possible to use the exhaust tunnel covers and adapt them or even an old engine undertray cut to suit? Or am I talking b8ll8cks?!
 
Well, the fitted exhaust tunnel cover would work fine as the heat shield for the middle bit of the exhaust pipe. There would need to be similar material covering the actual silencer & the first bit of pipe. It's basically what I was planning for the inside layer. It is fine to fill smallish gaps (4" would be fine for example), but the material is too weak to cover large areas.

Hence the polypropylene (PP) sheet. I gather that PP is often used to make bumpers etc. IIRC the undertray is made of ABS, but they could equally have used polypropylene since (i think) their properties are similar-ish. PP is more resilient to repeated flexing* than ABS is, and can be heatformed unlike ABS, but both are pretty tough. I have no idea whether 1.5mm is thick enough though.



* it can even be used to make hinges! For example, the lid on tic-tac containers is PP.
 
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