to then cut into that so close to the fold takes what little rigidity and strength away, this is basic structural stuff, you don't need to model it in CAD/FEA to see the issues (which is why I am amazed at a self-professed Structural engineer can post such bollocks)
I don't think anyone has suggested going so close to the fold, you started with the ill founded comments well before someone posted an image which showed an example which I agree is extreme. In fact to some degree it was a bit of a let off for you.
The basic technique of enlarging a hole and fitting a larger cover (shear panel) with several well positioned fasteners is neither unsound nor dangerous if done correctly.
They even use the technique to patch up structural panels of aircraft.
A flat sheet of ali has sod all strength against compressive loads without being formed, much like a sheet of paper won't support any load as a flat sheet, but if you put a couple of folds in it and make it into a channel, then close the open side (like the shear panel does), suddenly it can take compressive loads.
True, but then my son when he was 6 could have told me that.
so after all that, you actually agree that it's a stupid thing to do, but you just can't bear to say that in so many words?
(I had already seen the picture and a few cars before this thread started, so I knew what was being done.)
Look, I just don't get how anybody can defend cutting the hole out in the chassis, it's only done because people are far too lazy to do the job properly and drop the tank.
Like I have said before, it's no skin of my nose if you want to trash your own car, but to post up how-to threads for others to follow is pushing it.
A l am sure if somebody asked Lotus to comment on the practice, I know what their reply would be, I also know that if one got involved in a serious accident where the Police took an interest, somebody could end up with problems (I have already gone through this with the Honda conversions, one customer had a Major head on, the Police impounded what was left of his car, then wanted chapter and verse on the conversion, the test data, product liability insurance cover, etc. - it does happen).
As the Mods have obviously taken an interest in this thread, maybe they would like to comment on the abuse I have received within this thread?