What is the typical steel/aluminum thickness range for vehicle full frames?

The typical steel/aluminum thickness range for vehicle full frames is indeed between 1/8 inch to 1/4 inch. This thickness range is chosen for several reasons related to structural integrity and weight considerations.

Full frames need to provide support and safety for the vehicle while also allowing for some flexibility to absorb impact during collisions. A thickness of 1/8 to 1/4 inch strikes a balance, offering sufficient strength to hold up the vehicle's weight and withstand stress while being light enough to avoid excessive weight that might negatively affect performance and fuel efficiency.

Thinner materials, such as those below 1/8 inch, might not provide the necessary strength and could be prone to bending or breaking under stress. Conversely, using materials thicker than 1/4 inch could lead to unnecessary weight, affecting the vehicle's handling and efficiency. The structural requirements of modern vehicles also dictate that the materials used must provide the right combination of strength and durability, which is effectively met within the selected range.