Consider heat forming kydex to challenge the bean can protector, used it a few times and it's pretty fun to work with.
That's an interesting idea. I'm looking at 0.028" or 0.040". It would be good to keep it thin, do you think that the 0.028" would offer enough protection as a bean can? Thanks for the suggestion.
I switched to 0.45mm aluminum bean can on this in hopes to conform it to the carbon shape. It was still hard and I have concerns about protection.
For ultimate protection I'm not sure which works work best, thicker = better protection but.093 (my only hands on experience) would certainly be overkill. I used some .093 for my downtube and I have full confidence that it would hold up to just about anything. If it was my project I'd buy a sheet of each as they are quite inexpensive. You'll have more material than you'll need. Cut out what you will need and test the remainder while sitting on top of some styrofoam to see how much deflection/deformation you get with various impacts. Might even want to try some thinner double layers with some RTV and make a sandwich.... Could make for some entertaining content. For not only the top tube but older bikes lacking tail gait protection on the upper down tube. That's a pain point for my bikes, and probably many others. https://www.pinkbike.com/forum/listcomments/?threadid=216758
Ok. I got the Kydex and made it happen. The 0.028" looks pretty good. Fingers crossed on the protection... Thanks again for the suggestion. This was a good one.
Could always try a spray mount adhesive to get the formed sheeting to fit on the frame, but it's only an idea as not entirely sure if it'll be okay with the paint finish.