i have a stripped hatch with dash and front half of carpet, so i can daily drive it. my question is if i were to make door panels what should i use? i figure the plastics will be easier but will have to buy thicker so it doesnt crack. here is what i have thaught of using
Alluminum:
3003
5052
2024

Garolite:
G-11
G-10
XX

Or maybe pet, or acrylic/pvc, or lastely abs

 

^

 

i tried making a template today and i came up to that problem. the inner part of the door isnt exactly flat it would be a pain to do it if i didnt cut it out

are you saying cut it with a grinder or air cut off tool?

and what type aluminumand thickness would be the easiest/most rewarding to work with?