Alluminum thickness for wall paneling as outlet box support

[ycgoat]

I have a new un-insulated metal building, the cheaper type with 2.5" square tubing ribs/framing on 5' centers and corrugated metal exterior siding. I am about to run conduit for lighting and will have a 5 gang switch box on one end and a 4 gang box on the other end. I was thinking of using something like Diamond spanned across the 5' (a 60"x8" piece) between the building framing, and recess the switch boxes through the diamond plate for structural support, to facilitate a good fit on the 5 gang cover, and add some garage asthetics. What thickness material would I need to avoid a lot of flex in the middle of the span? Has anyone done anything like this with good results or have any lessons learned when they tried it.

 

[kbs2244]

i would use a wood 1x8, painted black.
It would be stiffer, cheaper, and easier to make the holes in

 

[ycgoat]

Yeh, I know wood would be easier, but I was thinking I wanted to stay with metal. I am considering using a piece of 20 ga metal stud trimmed and folded to fit inbbetween the framing members, then covering it with some light duty or faux diamond plate, but not sure that would not look very tacky.

 

[Milton Shaw]

A piece of metal stair side panels would be ideal for what you are asking to do. About 10" wide with a 1 1/2 flange on each side for stiffness. The actual stair sides are sheet metal with the flanges bent. You can get a light channel that is the same size but has thicker flanges for more strength. Any steel supply should have them. These are strong enough to be rigid between the 5' mounting distance you specified.