That's good! If you'd like to buy two sets of rear arches and two sets of new headlamps that'd be good too! Booked in @ Charlie's for the MOT next Friday.
Mine that I covered in vinyl were just cut out of hardboard using an old door card as a template. I have a spare door card that I will eventually be using that you are willing to borrow as a template if you decide to go down the make your own route.
Ok, I'll get some tomorrow and give it a go on Monday. Guess I'll need a jigsaw? Also need a engine lid seal, ignition switch, parcel shelf , speakers. Oh! And a big pot of filler and underseal. The list will get bigger, moT minus 7 days and counting. Eek!
I would go with ply, it handles any moisture a lot better than MDF although 4mm is the thinnest i think
Got mine from this guy. Very little fettling for door vents. http://www.ebay.co.uk/itm/VW-T2-Doo...arts_Vehicles_CarParts_SM&hash=item3385ec1862
You havent got the dimensions of the small panels that go at the rear above the engine by any chance?