BamZipPow -- But if the C-channel just holds the edge and there are fasteners right behind it to hold the panel up, isn't it just a matter of sizing the parts? Especially if it is protected by the airdam?
For the material, my vote is for
PolyMetal™. It has the strength of 5/8" plywood and 1/10th the weight. It's more expensive than plywood though.
Quote:
Product Description
PolyMetal sign panels are comprised of a recycled thermoplastic core sandwiched between two sheets of finished aluminum on one or two sides. The recycled thermoplastic core lends itself to resisting moisture.
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