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05 VLX centre fuel cover in floor


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My floor has become spongy in the centre above the fuel tank. Ive heard it’s made of honeycomb alloy. Anyone have any ideas as to where to purchase a new floor panel?

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It's popular to replace with hdpe; note that the carpet goes around the sides, so leave a gap.

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I have the same issue in my '99. What thickness HDPE should be used?

 

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Having made a lot of projects out of the HDPE and with that span I would recommend no less than 3/4” -19mm thick or you will have a lot of flex. I would even go as far as to recommend 25mm and route a lip on the edges so it will sit at the desired height for the extra stiffness. Underside lateral cross ribbing might let you get away with the 19mm. It will be heavy though. Someone who has actually made one would be the best source for guidance. Good luck.

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