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Dont know abot the sheet, but my arms are 1.5 .120 CM with 20 " of travel and estimating the final weight at 2200. What are you estimating the weight of your car?
Fabr,Another thing to think about is that running in the sand is entirely different than running in the desert (you've spoke many times of the desire to run in the desert). In the sand you support the weight of the buggy and it lands in a semi soft medium when it gets air. In the desert it's like landing on asphalt every time you jump. Add in the rocks and sometimes boulders that put themselves in your way and the impacts alone will take out the arms. In my opinion and I'm sure some will disagree but the desert is a factor of 2 or 3 harder and more abusive than the sand is on a vehicle.
If you look at the stress plots for the Barra2uda they prove that a properly designed (I hope it's yet to be beat upon) will be significantly stronger than a tube structure. Almost all the big boy off-road trucks run boxed sheet metal arms. They can't all be wrong...........there must be a reason they're not using tubes. Now my driving style might be severe compared to others but the fact remains that they bent. I even attempted to box the tubes on the single seater two different ways and they still bent, I'm now on the third set of tubed arms (at some point I'll probably retro-fit them with the new boxed design). Scooter's wife Dawn's also bent. He went to 4130 tube and additionally boxed them. I don't know how the 4130 ones held up this season. The first set of her's (mild steel) bent just like Samantha's............
Problem with FEA,as I found out recently while playing aroiund with Alibre FEA is that it is Vvery much a high tech witchcraft tool. Works very well but the saying "garbage in=garbage out" really applies to FEA. How ,for example, can you determine the load applied to anything when you have no way to measure what that load is?