Late at night, when I should be doing work or, better yet, sleeping, ideas spring to mind.  I’ve created a few small projects from big sheets of coroplast or polypropylene corrugated plastic.  This is the kind of material you see in use for yard signs.  They are big, cheap, sturdy (as long as you’re not bending it with the grain), and lightweight.  They can be bent or cut easily.  However, since it is polypropylene, it is fairly resistant to most glues, adhesives, and paints.

Duct tape and hot glue work well, but have their downsides.  The duct tape can be unsightly and not very good for “laminating” several layers together.  Hot glue works well for laminating layers, but it cools so fast that it’s hard to glue big sheets together.

Anyhow, all of this is to say I found a great website by Christine DeMerchant which provides a lot of information and insight on how to glue these materials together.