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I used black 4-mil coroplast sheets for my undertray. It was easy to work with, light as a feather, and easy to trim. I have three panels in place (one in front and two under the cabin on each side of the exhaust), and I'm working on a design for the rear. Calculations show an overall 5 MPG gain in combined city/highway over the stock underbody.
Just be careful about making a front undertray. If you don't allow proper ventillation from the engine compartment, you'll run hotter in the city, especially at red lights.
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