Materials Question

[eco86]

If you're going to vacuum form something, I would recommend either ABS or Polypropylene. Polypropylene is more resistant to impact, and forms easily with heat. If you're looking for a material outlet, McMaster Carr is a good web site, but probably wouldn't be worth it if you have to pay shipping on a 4'x8' sheet. Personally, I've been making panels on my car out of FRP (Fiber-Reinforced Plastic). A 4'x8' sheet of 3/32" FRP is $30 something at Home Depot, and seems to hold up nicely. Only problem with FRP is that it is kind of heavy, but I'm doing primarily highway driving, so that isn't as much of a concern for me.