So I'd really like to have a belly pan installed. There is no cheap or free source of coroplast in my area. I've been trying to get my friends at the home depot to give me some old signs, but nothing yet.
I was thinking today, how about foil wrapped rigid insulation? The 1" stuff is plenty rigid for the task. It could be used without a frame for small spans. (I think) I'd have to use strapping or some other light material too hook it to the car.
It is light. Relatively inflammable. The joints could be taped with foil tape if need be.
It would be really easy to work with. It would be really easy to replace it if it broke too.
The question is, would it take moisture/road debris? How well will it wear?
The foil covered foam insulation isn't as durable as you might think. You'll have to put something over to keep it from gitting torn up from road debris. The aluminum foil will also have a tendency to peel back when the edge is subjected to airflow. A layer of corplast would work...or even some aluminum flashing is possible. Fer better durability...fiberglass over it might be a better choice.
I think the the max temp on it is around 250?F...slightly higher than coroplast. I used the ?" R-Matte foil based sheets.
I will be using this as a filling in a coroplast sandwich it fer my aerocap.