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I've been inspired Snax. I went to Home Depot yesterday and picked up 10 feet of 1/2 inch diameter plastic tubing and I have put it inside of my rims. Worked well just as you said.
SO.
I am using this method now to create a different type of flat wheel cover. I am aiming now to make it as minimal and easy to removed as possible so this is what I have come up with and am working on at the moment.
They are not really "flat" but they will fill the large holes in my rims to reduce turbulence.
I have taken a ton of measurements and done some prototyping with cardboard. Right now I am currently working on perfecting the design in Solidworks so I can just print out the design on paper and easily trace the cover geometry onto two pieces of coroplast. The modeling and measuring is probably the hardest part of creating them this way however it will yield very smooth, uniform, and professional looking results (granted I pull it off well when I cut out the design)
Basically I will drill the large part of these covers into the tubing and the middle section will sit on the middle cap of the wheels secured with velcro. This will ensure that the coroplast sits flush inside my rims and does not create any extra drag when installed.
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