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Try:
PVC closed-cell boards (Sintra, Celtec,etc) - Inexpensive, lightweight, fire-resistant and very easy fabrication techniques.
Thermoplastic acrylic-polyvinyl chloride alloy sheet (Kydex) - Very tough and abrasion, chemical & fire resistant. Very easy to work with.
Low Weight Reinforced Thermoplastics (LWRT) - Lightweight plastic composites with low thermal expansion and good mechanical and high impact properties.
High-density polyethylene (HDPE -cutting boards) - High impact properties and low coefficient of friction. Already used as auto & truck underbody splash shields & skid plates.
General purpose ABS sheets - High impact & strength properties, Easy to work with and a common auto trim material.
Good luck on your material choices.
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