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#13404
Hi Bob,

I just buy 3mm MDF from Bunnings, about $14 for a 2.4 x 1.2 metre sheet. Then to cut it, I mark out the pattern and use my Bosch multitool with a wide blade, cuts through it like butter and gives you a nice clean edge.

You can then glue your sewn door panel over the top or depending on what type of sewing machine you have, you can sew straight through the MDF.

Cheers


Bill.
#13419
Hi Bob,

I haven't had any problems using it, but if you were concerned about moisture ingress damaging the panel, then you could always give the MDF a coat of sealer or PVA glue to help waterproof it. Also you'd want a clear plastic sheet between the panel and the internal door skin openings, to keep out water that may run down past the window seals.

By the way did you end up making a decision on what sewing machine to get?

Cheers


Bill.
#13456
There are many alternative options. PVC sheet is also very popular if you want to stick with plastic. Other options are 1/8 plywood, Aluminum, Black automotive panel board, 1/8 hard board.
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