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Old 4 Mar 2009
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Fuel Line Guard / Fuel Tank Guard

Does anyone have any experience of fabricating either of these? In my case it is for a car - you know, one of those things where only 2 wheels are driven , in which we will try our hand at some of the more substantial pistes in Morocco.

I have a sump guard on order - which I will fit - but I was also concerned that one stray kicked up rock could do a whole lot of serious damage.

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Old 4 Mar 2009
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I understand your BMW is fairly old therefore the underside is quite open? Any chance of posting a few underside pics?

Personally, i would purchase a load of sheet metal, get underneath and start measuring. Find whats vulnerable and cut a cover to suit. you can use a series of angle steel lengths to make brackets all bolted together. find a suitable mount point, drill some more holes and bolt it all in place. 3mm will prob suffice as protection plates for minor things your worried about. I would imagine your sump guard will be in the region of 5-8mm thick. worth using something similar for the diffs on the axles.

You should be able to get it done in a long weekend with the steel, bolts, spanners, hammer, angle grinder and a drill.

Good luck

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Old 4 Mar 2009
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I have seen it on a ramp - and inspected the underside - and looks in good condition - at the moment!!!

I can't foresee having too many problems with the pipes - but the fuel tank will be slightly more challenging.

I am not intending to go too mad off road - but more a case of investing a little bit of money now - might save an expensive (££££ and time) problem in the future.

I was looking at whatever metal sheeting I can find that can be bent by brute force and ignorance.

I will let you know how I get on.
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Old 5 Mar 2009
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If I were taking a car, I'd put on a good heavy set of mud flaps like the rally cars use to try and stop the stones being flung up too far.
I'd lift the suspension too - maybe using spacers under the springs, or the spacers that you can insert into the spring? (caravaners use them)
And then get the tallest tyres I could get under the arches.

Rather than armour plate the underneath of the car, it might be easier to just re-route fuel and brake lines inside the car, but to be fair the locals seem to get on ok without it.
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Old 5 Mar 2009
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Maybe have a look at what ChrisS did with his Merc:

Sahara Overland ~ Mercedes 190 for Sahara

Last edited by roamingyak.org; 6 Mar 2009 at 11:11.
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Old 9 Mar 2009
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We picked the car up on Saturday.

I jacked it up to try and fit the sump guard - even though I knew they hadn't ordered the fitting kit.

Checked the fuel and brake lines - and they are recessed - the front protected by a chassis member - and the rear isn't the lowest point. For the time/cost/hassle of fitting a guard - I will take the risk.
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