intercoolers I have - we have this roll of aluminum and its probably 0.020" thick and a foot or so wide. I was envisioning using one of those flat-bed paper cutters to cut the pieces and using a 'brake' to bend the ends. Then just use rivets to hold the pieces together and voila. Aluminum is easy to work with and it will flex - plastic might prove to be a cumbersome material to work with/shape/bond. Good luck!