I located one lumber yard that lists Thermo-Ply. It turns out they haven’t sold Thermo-ply in 30 years, something about shear factor for building materials. I’m not finding it available anywhere. I got creative with some web searches and called up a couple Automotive Upholstery shops. I found Automotive Interiors out of Belchertown, Ma. sells Cowlboard Waterproof Cardboard Door Panel Board 32”x48”, 1/8” thick Natural color.
https://www.automotiveinteriors.com/waterproof-cardboard-door-panel-board-cowlboard-p/cowl-dp.htm I would need 7 sheets of that.
Royal out of Spokane Wa. Sells Water Repellant Panel Board Black 39”x65”
https://royaluph.com/product/39-x-65-water-repellant-panel-board-black/ I would need 4 sheets of that.
I went to a local shop and spoke with the Upholsterer, He was interested in my Panel truck project and gave me a sample of door panel board. He had Two kinds of panel board. A Black door panel board that is 1/8” thick, and a hat tray board that is Tan and painted Black on the side with a light rhino skin texture that is 1/16” thick. He’s seen both warp due to moisture. The original panel board is Black to the core and painted Grey on the side with a rhino skin texture, measures about 1/16” thick. I tried the sample in my truck and it does fit in the channel at the bottom of the cargo wall.
I like the idea of going to a place like Royal. I could spend hours digging through bolts of fabric and looking at bits and pieces for various projects. I tried to find a local store like that, but only came up with a wholesale distributor. I might get the suburban headliner, I noticed Jim Carter lists uncut panels with a patern drawn on that you trim. Shipping would add to the cost. My original cargo panels had a rhino skin texture. Jmmmn37, Did the panels you got from Classic Parts have any texture, or are they smooth? If they have the rhino skin texture I could spring for the shipping, otherwise I’ll go to a local auto upholsterer for the panels.