Sheet aluminum?
 

Has anyone ever tried sheet aluminum (the kind from Home Depot that comes in a roll) for wheel covers? I know it is thin but i think it will do the job. Also it could be used for a grill block and other aerodynamic mods. What do you think?

If it's anything like the Alcoa aluminum trim coil that tradesmen buy at a vinyl siding wholesaler, it might be too thin for wheel covers unless you're willing to reinforce it with something...but would be great for grill blocking.

Most often I hear of smooth wheel covers being made from pizza pans. Sheet metal is going to be too thin.

I think it would do the job well for a wheel cover, if reinforced. If riveted all around the wheel well, with a cross bar along the bottom. The hard, and important thing would be to rivet in on with out any slack in the Al.

On second thought, if it was my car, I'd be nervous about the rivets ripping out. Al is so soft... I don't know... maybe more reinforcement, like an X on top of the cross bar. And then how do you remove it when you get a flat...
....it would be a good grill block though..