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I was going to suggest using a product like "Thompsons Water Seal "
The sides of the cardboard would then have to be sealed shut. This could be done in one of several ways - clear packaging tape, duct tape, a thick coat of paint that gets into the crevices ...etc etc .
The idea of using cardboard seems ridiculous at first, but i must admit that cardboard is a readily available source of cheap material that is more flexible than Coroplast.
Coroplast isn't good for compound curves, but thin cardboard can be shaped into just about any shape.
One drawback : Cardboard is heavier than Coroplast and will become even heavier with a few layers of water seal.
It's an interesting idea none-the-less.
I would like to see how it turns out !
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