1/4" T6061 aluminum usually does a good job. We were using 5/16" for the front skid plate replacement but that turned out to be a waste of metal. If the un-reinforced square area isn't more than say about 2'x2' 1/4" works fine even for heavy bashing. If you're not planning on slamming the weight of the vehicle on it it will certainly work. You can go to 5/16" or 3/8" for larger square areas but at that point you really need to consider supports and mounting more than the metal thickness.

For what you sound like your doing I'd do 1/4" 6061. It'll save weight. Just my 2 cents.

Edward


'97 Montero Sport LS 5-Speed 3.5L conversion
SAS Dana 44s & ARBs, 35" Yoko Geolandar M/Ts
NP231 B4R doubler/Terra Low231/RP 5.38 229:1
'99 Montero Sport Limited 4WD SAS 3-link project
'03 Montero Sport Limited AWD
'97 Montero Sport LS 5-Speed 4WD