Might want to check Walli mart for a foam core product. Its a high density foamed core (PP or PE) with smooth surfaces. It is actually stiffer than coroplas and might be easier to work with. Baring that, after local/regional/city elections a lot of coroplas is wasted in political advertising. In this cold weather you might want to consider making a lower grill block of plate. The opening below the front bumper.
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