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Hello, new member here who came looking for help on a project and who beleives in giving back. And, I have an interest in this anyway as I have a full size reg cab truck with ginormous cavities under the bed. An underbody cover would likely be a huge help for my truck's fuel efficiency.
I was also going to suggest the holes in one sheet/second sheet as a backer. The heated iron ball in each hole would eliminate the rough edge problem. And, no need to worry about stress on what fastens the two sheets together if they are attached with glue across the entire section. This will both help stiffen the two sheets together and spread any stress across the entire pair of sheets. I would also go at it by cutting the holes, then gluing the sheets, then applying the iron balls. Vacuum would likely not work well unless the corplast were heated first anyway, because the corplast would need to be able to stretch and it's not going to do that at room temp. Since heat must be applied anyway, might as well get the iron balls out.
For the fellow with the Suburban and the overheating issue due to the inadvertent spoiler, what about putting a wing right in front of that piece with the flat to the bottom and the curve to the top? A wing generates lift by putting a low pressure area over the top, so the plane is actually sucked up into the air from the top as much as lifted from the bottom. This would help draw air out of the engine bay, but would not generate so much lift that it would be a problem for a Suburban since the vacuum would be filled with engine bay air.
Hope some of this helps.
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