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If you paint the cardboard it should last longer. For attaching your grill block, maybe you can attach brackets made of sheet metal to places that already have screws or bolts.
My 94 CX hatchback gets about 50 MPG on the highway going about 55 MPH. I drove a little over 500 miles on a tank. I tightened the timing belt, fixed a rich mixture problem and advanced the ignition timing a little before getting that result.
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