By adding panel details such as
angle aluminum trim to edges, with
subsequent neat fastener/hardware,
each panel will be strengthened.
However, with adding interior decking
suitably fastened to the four "walls,"
the panels will be stiffened.
Now, adding exterior details such as
lifting handles with fender washers
and carefully cut mounting hardware to
reduce thread protrusion will also add
stiffness.
In difficult situations, a plate of 1/16"
steel, painted accordingly, and mounted
inside and under the fender washers, will
prevent the panels from bowing out while
the cabinet is lifted with the handles.
Doubling up on the very bottom and very top
1/8" aluminum plates with suitable fastening
to the four walls will impart strength and
stiffness to the chassis assembly.
When you get all your chassis plates assembled
and drilled, and maybe Pal-Nutted, it's a good
thing to send them down to your local metal
plating shop for a dip in the Milspec Iridium
(Class-III) tanks and that will liven up the
conductivity and eliminate the aluminum
corrosion.
Hal
{snip}
I already have a .125" thick aluminum
front rack panel.
How heavy should I go on
the remaining panels?
{snip}
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