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I used 4 mil (since it was what the campaign signs were made out of). I had a 2x6 at the end of my trunk lid, and added additional supports inside to give it a bow in the middle. This prevented the sagging, and added a surprising amount of stiffness to the coroplast. Make sure you have a good fit, and that it is attached sufficiently well. You don't want to have something sticking up and catch the wind at 60mph, I just don't see it ending well, no matter how strong your adhesive is!
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