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I use cereal box cardboard to make 1/4 scale prototypes of compound shapes for fairings. This translates to 4mm coroplast full scale in stiffness. I use .015" Lexan for slot car bodies and it is quite flexible. Coating the aluminum with a coat of resin or plastic would help the denting somewhat. We use plywood laminated between aluminum or melamine for railcar panels. Check into paper model techniques for getting the shapes you want.
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