Originally Posted by
Ben Burtle
There are limitations when it comes to reinforcing a thermoformed product.
From a making it stand point they start with a flat sheet of a given thickness and then heat it up and suck it into a mold to make the body. Because of that you really can't make certain area's "thicker" then others. How you mold the body can cause thinner spots or you can add features to the body to make certain areas stronger depending on the contours and such but at the end of the day you kind of get what you get and in this case it is a lexan body that gets slammed on by a 6lb truck going 30+mph over and over and over again.