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I've got the welding rod, I could do a sample part.
Connecting the rods in the flutes with the semi- or completely buried perimeter pieces: Just [spot] welding it might work, or it might melt the coroplast. Bend a tab on the through pieces and you could tie it off with thread and paint that with epoxy. Apply any compound curvature to the sheet coroplast before rigidifying the ends.
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