I may as well start a new thread instead of completely changing a previous post under S3 Serviced
Thanks Lyrac for the points that u made in ur post about the sump guard.
I have already had lengthy discussions with a freind who is an metals engineer. We finally came to the conclusion that tempered steel would be an ideal material to use as a guard. Mild steel would flex upwards upon impact and possibly still damage the sump, where as tempered steel would most likely crack upon a HARD impact and take the damage away from the sump.
Another material which i think would be ideal too is timber!! Ok dont laugh but if u think about it its ideal for taking a good knock, wont flex, wont crack, and can wear away if and when u bottom out the car. The only problem i forsee is keeping it waterproofed enough to last long enough.!!
The steel guard will have with out a doubt channels and ducts cut into it to direct air upward sinto the engine bay to aid cooling and hopefully prevent excessive under bonnet temperatures.
I personally wouldnt go for a rubber based product to cushion the guard against sump due to the extreme heat under there and the rigidity of the product too. I have already looked into a product that can withstand extreme heat, waterproof and has dampening qualities.
Only thing i need to do now is get under the car and start the project !!