QUOTE(Always Looking @ Sep 25 2006, 09:52 AM)
Great info. What wood are you, Brian, going to use. I was thinking of mocking one up in cardboard today.
Dan
Hi Dan,
The "5mm Exterior Hardwood" ply found at Home Depot is tempting, but I wouldn't recommend it. I did the "boil test" on it to see if it was worthwhile for marine applications (good marine or exterior grade ply will withstand being boiled indefinitely). The sample fell apart in one hour.
No the 914 isn't a marine application... BUT, the temperature swings inside a car a very brutal. Add a little humidity swing, and your console will probably start warping after the first summer.
"First Class" is some marine ply made from "Okuome" or "Meranti". You can find it in 3mm, 4mm, 5mm, 6mm, etc thicknesses. Pricey starting at $30/40 sheet for thin stuff.. but it is very stable and won't move on you. Perhaps, while you are in there, you can build some really nice new door panels too?
"Second Best" is
MDO (Medium Density
OVERLAY) plywood. Used for signmaking (NOT MDF Medium Density Fiberboard). I belive 1/4" is a thin as you can buy it, but it is also dimensionally stable, water and weather proof, and more readily available all over the country.
If you "must" go "cheap" using the Home Depot stuff.. make sure you seal it really well with some polyurethane after you've completed the last cut. Don't let the moisture migrate in or out (epoxy is best.. but the cost of using that negates the "savings" of using cheap plywood).