Drew, coroplast is not foamboard. In the ICC technical bulletin I point as reference, working with foam was explained because foam is used to stabilise artefacts in the coroplast box.
Coroplast box in 5-6mm are much more solid that .060 cardboard box. Channel walls get also heavier with the thickness.
But in both case, it is better to stack same size boxes only.
I cannot comment a 24x36"cardboard box as the max. size I manipulated is 20x24". But I can comment on Coroplast boxes 40"x 60" in 6mm with my heating technique. I think the next time I will do one, I will test it like Richard Ritter who stand on his camera bed. I don't think a cardboard box will like this treatment.
24x36" should be OK for matted prints, still not so large and probably very similar to your 24x30" Darin.
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