My carbon effect ABS sheet arrived today and I've tried to make a boot box cover with it. The inside of my car is trimmed with it, as is the surround to the boot box. I can't make it work though.

I fastened it to a nice new piano hinge with black rivets which caused it to buckle. Damn. removed the rivets and the plastic is ok but the hinge is totaled.

What can I use to support the plastic to keep it flat on the car?
what can I use for a hinge that doesn't look like it's off a gate?

Try riviting a piece of 10mm x 10mm x 2mm angle ally under the plastic with the piano hinge. Available from B&Q.

An excelent idea. B&Q was open, I bought the aly and a new hinge. PUed and riveted and straight as you like.

Glad it worked.