Foam shit in sills

[Sanity Clause]

Quote:
I might have a search round the internet, see if I can find the stuff Nissan use, would feel better about using something like that if a manufaturer uses it aswell.

My car is having a roll cage anyway, but just wondering more ways to strengthen it

The shell needs to flex a certain amount.

It depends on what you intend doing with your car, of course. But I'd suggest that you don't want to make it too stiff, otherwise you could start getting cracks appearing, in places like at the bottom on the screen pillars.

Having said that, you'd probably have to be driving on some pretty rough roads for a while for that to happen.

Seam welding the chassis will help to strengthen and stiffen, but don't weld continously. Leave gaps. Weld 2 to 3cm, then leave a 2 to 3cm gap, and so on.

Double-skinning the sills will also help a little.

A lot of effort for a small gain, though. A properly fitted roll cage will provide most of the stiffness you require.