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Originally Posted by HydroJim
I'm going to use aluminum bar. I'll use the bar to build a frame and then attach coroplast to the metal frame. Do you think I should use bolts, self-tappers, or rivets for that?
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I had been thinking about using PVC tubing, as it's light, and you can get all sorts of connecting parts - bends, T's, X's .
It'll flex, then spring back to what it was.
There's also all sorts of kit to clamp 'm down.
I've been thinking about glueing a number of L-brackets on the hatch & window with heavy duty double sided tape.
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In order to make the hatch still functional, the gap between the car and the coroplast will obviously have to be unsealed permanently.
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If it's light enough, you can mount it entirely on the hatch, so the tail moves with it.
Foamed edges may seal it flush against the bumper.
I'll have to settle for a box cavity though - anything bigger is sure to attract unwanted and unpleasant attention.