[Zedn]

Provided they are welded properly, 1.6 will be fine for baffles. If you have seen them come loose its likely they were not welded properly.

If the tank is 75ltrs, then the mass of the fuel is around 55kgs. If there is 2 baffles then there is 18kgs in each section when full. You will have to go around a corner pretty damn fast for that to rip 1.6mm apart, especially when it is welded on 3 or all 4 sides.

Mike not sure what your plan is but folding the edges of the baffles and welding them flat against the sides and bottom works well.