How do I create this?

[zx9]

Looks like the corrugation could be an issue too...

Can you offset the corrugation to a third of the length rather than in the middle? That way you can stagger them when fitting to the vehicle.

 

[ajlelectronics]

Can you offset the corrugation to a third of the length rather than in the middle? That way you can stagger them when fitting to the vehicle.

That is what I have in mind, although if I thin the wall down, I may not need them at all.

 

[daedalusminos]

I would think something with a 3mm wall should suffice - I'd also select your wall thickness to be a multiple of your extruded width and go for enough perimeters to make it solid. If you design like this you can flip one round so it doesn't interfere with the other:

Here I've also shifted and copied the outer horizontally to form the inner rather than an offset, this will maintain your exact perimeters on the 45° slopes - results in a slightly thinner wall....

 

[Pete.]

3mm wall I think might pull the sides in on the overrun.

 

[ajlelectronics]

Here is my latest experiment. The outer ends 20mm at 5mm thick, tapering to 1mm in the middle.