I recall having read an article in Street Rodder some years back explaining how to make permanent parts out of poster board. As I recall, the procedure involved making the part and making numerous small holes in the poster board with a leather punch. Next, you coat your prototype with fiberglass resin and allow it to cure. Layering on fiberglass cloth was presented for heavier duty applications. I have never tried this, but it may have merit for one-off aero bits.
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