The AL might be able to take more of a beating that the coroplast without breaking but it'll bend quite easy, even 2 sheets bonded together. Now if you bonded to sheets together with a piece of honey comb plastic in between that would be a winner...

 

hmmmm that could be a good option...

 

Yeah I thought coroplast was aluminum with plastic in between but it isnt, so yeah I would be all for you using a crap load of epoxy and bonding the AL and coroplast together.

 

I've got it printed up, but its not in-hand at the moment. I'll let you know how it fits on an NB on Monday

 

Leafy, I think you were picturing dibond, which I will have to compare pricing on

 

I'm not sure why more people don't use PVC foam board (Sintra is a common brand name) for splitters - cost?

It's closed cell (won't absorb water), light weight, rigid, very easy to cut, and comes in numerous colors to fit your design fancy.

It's more difficult to source compared to plywood from HD, however, call a local sign shop and ask who their supplier is.

Sintra® PVC Foam

-Zach

 

looks like a 1/2" thick 48x96 sheet is $250....
im looking to pay closer to $40 for AL

 

With 5 minutes of google I found what you need for way less: BLACK EXPANDED PVC SHEET Plastic Sheets

I've bought it locally from a metro-Boston sign shop for less plus I saved on shipping costs (which can be brutal on sheet goods).

-Zach