5 Cars with Thickest Sheet Metal (List)

Looking for a car that can take a beating? Check out our list of cars with the thickest sheet metal! These vehicles are designed to withstand major impacts without denting or bending. Whether you’re looking for a family car or a sports car, we have got you covered.

So, what are the cars with the thickest sheet metal? Keep reading to find out!

Why Do Different Manufactures Use Different Sheet Metals?

Sheet Metal has been used in the car manufacturing industry for centuries. The reason is very simple, sheet metal can be rolled, bent, or welded. That’s why the car’s structural components, chassis, and internal components are designed using sheet metal.

Now, the thickness and type of sheet metal vary within the vehicle as well. The exterior parts are usually made from Aluminum to make the car lightweight, while the interior cage is made of high-strength steel and has great thickness.

Similarly, the thickness also varies from manufacturer to manufacturer because they have their own priorities. For example, some companies might prioritize safety while others might focus on performance. Some are interested in making the car lightweight, while others focus on making it sturdy and heavy. Additionally, the type of metal used can also affect a car’s weight, fuel efficiency, and price.

Which Car Brands Use the Thickest Sheet Metal?

The automotive brands haven’t disclosed the thickness of sheet metal they use in the manufacturing of their automobiles.

However, from the information gathered through different car forums, I have made a list of brands that are believed the thickest sheet metals. All of these are high-end luxury brands which include Mercedes-Benz, BMW, Audi, VW, Volvo, and Porsche.

Car with Thickest Sheet Metal

Their no specification with the name Sheet Metal Thickness in a car’s manual. Nor have companies mentioned how thick the sheets they use. But based on the external resistance to impact and dents, we have some picks from some top car forums. Here’s a look at our top picks:

Mercedes-Benz S-Class

A great luxury car from Mercedes-Benz, S-Class, is the car with one of the thickest sheet metals. The company uses high-strength steel for the very thick body structure.

Mercedes-Benz S-Class is a full-size luxury sedan produced by German automaker Mercedes-Benz. It was introduced in 1972 as the successor to the Mercedes-Benz 600 and features a range of V8s and V12 engines.

Also read: 6 Mercedes-Benz Models to Avoid (with Years)

Jaguar XJL SuperSport

The XJL Supersport is a full-size luxury sedan produced by British automaker Jaguar Land Rover. It was introduced in 2009 as the most powerful and fastest version of the XJ and features a supercharged V8 engine with 550 hp and 502 lb-ft of torque.

VW Phaeton

VW Phaeton is also a great choice if you’re looking for a car with thick sheet metal. This car is made with a high-strength steel body structure that can withstand greater impact.

VW Phaeton is a full-size luxury sedan that was produced by German automaker Volkswagen. It was designed to compete with other high-end luxury cars such as the BMW 7 Series and the Mercedes-Benz S-Class. The Phaeton was equipped with a range of V6 and V8 engines.

Audi A8

The Audi A8 is also on the list of cars with thick sheet metal. This car uses a mix of aluminum and steel for the body structure, which makes it very strong and durable.

The Audi A8 is a four-door sedan produced by the German automaker Audi. It was introduced in 1994 as the successor to the Audi V8 and features all-aluminum construction, a Multitronic CVT transmission, and a 4.2L V8 engine.

BMW 7 Series

The BMW 7 Series is a full-size luxury sedan produced by German automaker BMW. It was introduced in 1977 as the successor to the BMW E3 and features a range of inline-six and V8 engines.

Each of these cars is equipped with some of the thickest sheet metal on the market.

What are the Advantages of Thick Sheet Metal?

There are multiple reasons why sheet metals have been used by automakers for designing cars. Similarly, using thick sheet metal has also been advantageous for auto manufacturers.

Resistant to Bending

Many mechanics judge the thickness of the car by tapping onto the front bonnet of the car. The sound and bending tell them how thick the metal sheet is used. Ideally speaking, adding more thickness to the exterior sides, like the fenders, and the hood will make them more resistant to denting and impact.

Sturdy Frame and Chassis

Since sheet metal is also used to design the structure and frame of the car. Adding more thickness will make the car strong and more protective in case of an accident.

Less Cabin Noise and Vibration

A thick sheet ensures the car remains vibration-free and less amount of noise reaches inside the cabin.

Also read: 15 Cars that NEVER Rust (100% Galvanised)

What are the Disadvantages of Thick Sheet Metal?

Thick Sheets Add More Weight

At this point, I want to mention that adding more thick sheets isn’t always advantageous for us. A thick sheet of metal directly adds more weight to your car.

Thickness Doesn’t Mean More Protection!

Moreover, more thickness doesn’t necessarily mean more safety and protection. Safety depends upon how the structure of the car is designed. Sheet thickness does have some role in it, but the car’s safety doesn’t necessarily lie on it. Nowadays, cars are designed such that the frontal body gets destroyed absorbing the impact force and the user remains safe during an accident.

Is Thick Sheet Metal Used for All Body Parts?

No, thick sheet metal is not used for all body parts. In fact, all parts of the car do have variable thicknesses of sheet metal. For instance, the exterior parts of the car like its doors, hood, fenders, and trunk may be thin. While a thick metal sheet, usually high-strength steel, is used for designing the internal cage/ frame and chassis of the car.

However, for people, the visible thickness is the one that is used for outside parts. So, normally they are interested in gauging the thickness of these parts only.

How Does the Thickness of Sheet Metal Affect the Strength of the Chassis of a Car?

The chassis is the primary load-bearing component of the car. It is the main structural component on which the frame has to stand. This particular component must be much stronger and thicker than the rest of the car.

Increasing the thickness of sheet metal in this section will definitely affect the strength of the chassis of a car. The thicker the sheet metal, the stronger the chassis will be. This is because thick sheet metal is more resistant to bending and denting.

What is the Sheet Metal Thickness of Most Durable Cars?

The sheet metal thickness of cars is usually defined in terms of a unit chart referred to as the gauge. There is a chart defining the conversion from gauge to inches and millimeters. You will find gauge conversion charts for different materials on the Internet.

The sheet metal thickness of most durable cars is usually between 20 gauge to 28 gauge. This is because thicker sheet metal is more resistant to bending and denting. Additionally, it can also help to improve fuel efficiency and reduce noise levels.

What is the Best Type of Sheet Metal for a Car?

A car may consist of different types of sheet metal. There is no best type of sheet metal for a car. This is because each type of metal has its own unique advantages and disadvantages, and is used for designing different portions of the car.

In automotive, mostly metal sheets of Aluminum and High-strength steel are common. However, a few other metals, such as boron steel, and mild steel, are also used.

Aluminum is one of the most popular types of sheet metal used for cars. It is usually used for the front portion and exterior components. It’s lightweight yet strong, making it ideal for use in vehicles. Additionally, it’s also corrosion resistant and can help to improve fuel efficiency.

High-strength steel is another popular type of thick sheet metal. It’s extremely strong and durable, making it ideal for use in chassis of the cars. Moreover, it is also resistant to corrosion and can withstand large impact forces.

Final Words

The thickness of the sheet metal is an important factor to consider when designing cars. It helps to improve the strength and durability of the car. Additionally, it can also help to improve fuel efficiency and reduce noise levels. However, it’s important to note that thickness doesn’t necessarily mean more safety and protection. Safety depends upon how the structure of the car is designed.