Plastic selection for back door trim.

Fairly self explanatory, what would be a good plastic to use as a replacement door card? The hardboard I have currently is looking tired and is not really robust enough as a couple of tool handles have found their way through it and it is not happy about getting wet. Don't want aluminium as it will be too loud and rattle and need covering. Had thought about abs but I worry that it's a little brittle in thin sections? I also thought about stokbord which is ideal but I don't have any off cuts and a full sheet is mega bucks. What are my options?

I used textured 3mm ABS sheet for the dash on the trials car. It gets a fairly hard life and so far no damage. You can get it on eBay for a reasonable price .

Another option is PVC foam board but you'd probably need about 6mm thickness. The range of colours is pretty limited as well.

I used 3mm grey PVC to make my dash board box (then wrapped in black vinyl) and also for the front recovery point covers. If you heat it up it will bend, just keep it in place whilst it cools.

Mind it isn't cheap to buy, especially if you want a big sheet.

An alternative would be [marine] ply, it's waterproof and reasonably durable, you could paint it or wrap in vinyl/carpet.

The thinner the better as I'm trying to maximize internal volume. PVC sounds good. Not particularly bothered about colour as long as it's not transparent. Will price some up.

Check the yellow pages for sign manufacturers in your area and then give them a call and ask them about coroplast - it's a corrugated plastic sheet very similar to corrugated cardboard and I have used it successfully to make replacement door cards, essentially replacing the hardboard & reusing the original vinyl.

My local sign manufacturer will sell me what ever size piece I need. He will also sell 3mm PVC sheet which I've used to do fairings for roof racks.