A little over a year ago I tried an experiment using some foam-cored sheets and simply taped them on.
Now, with "my" i-MiEV (wife has her 'own'), I'd like to continue the experimentation. The material I'll use is a simple foam sandwich which I can epoxy sheathe with either fibreglass deckcloth or some very thin carbon cloth. Not a problem to produce a thin yet stiff fender skirt.The issue is how to attach it -
After considering various cantilevered clamping techniques (which would only work in a couple of spots) I've come to the conclusion that a simple rivnut should work in both the sheet metal as well as the plastic bumper, with six rivnuts per side. The disadvantage is that I will now have six permanant holes in the wheelwell periphery. I could probably camouflage the fasteners (either with or without the fender skirt) with a dab of white paint.
Since both the sheet metal and bumper are very thin I think I need to use soft aluminum rivnuts, after appropriately coating the drilled hole to prevent galvanic corrosion. I was unable to find any plastic rivnuts which would do the same thing.
1. I am open to suggestions for fender skirt attaching schemes
2. Anyone know of any plastic rivnuts?
3. Should I be concerned about corrosion between the aluminum rivnut and the car's sheet metal, recognizing that the rivnut is less noble?