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I built up my sideskirts on the E150 with 1" thick pink styrofoam from Lowes, skinned them with the $35 fiberglass shower panels, and then glassed around the edges. The fiberglass panels are kind of brittle, because they are made with short strand for a nice surface finish. I plan to do a rear wheel panel like yours, but haven't decided how to build it yet. I think I'm going to do a sandwich construction with a thin aluminum sheet (0.050" from Alro) and a surface panel of the fiberglass shower panel for a nice smooth surface. The big tubes of Loctite Premium 3x work well on aluminum, paint, styrofoam and fiberglass. I'm not sure if it sticks to coroplast, I haven't tried it yet. But the big tube is a good value, only very slightly more expensive than the little 10oz tubes.
How tough is the wheelwell sheet you made? I was going for something that is "self-supporting" with the sandwich construction, but I'm not opposed to putting an aluminum c-channel inside to give it some strength.
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