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Great post GS! I did the same for my trunk lid. It had started to develop hairline cracks where the rack was mounted. So I took an oldmarine typebattery box that I had laying around. As far as I could tell it was made of ABS and the thickness was around 3/8ths of an inch. I cut out the pieces to fit the inside of the trunk, heated them with a 500w halogen shop light until they were soft and then formed them to the trunk. After they cooled I used the ABS glue to bond them and then drilled the holes for my rack. I tested it this summer when we loaded up for a week long trip out to Oregon and back. I believe the bag I hadstrapped to the rack weighed in at close to 20 lbs, but I had no problem due to the fix I had made.
 
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