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The foam core I've used is still limited to 2D curves, because one face is still paper. Re-gluing the other face after bending does sound like a good way to get a smooth curve. However, it would still need epoxy encapsulation for rainy days. For 3-D forming, Coroplast can be vacuum-formed, but it takes some technique along with the usual equipment. For a gentle shape like an overlapping wheel skirt, you can persuade Coroplast with a hot air gun.
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