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Old 04-11-2012, 11:05 AM
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PVC foamboard (expanded PVC) can be heated and bent at lower temperatures than ABS, and it's also way less expensive than ABS. A 4' by 8' sheet of 6MM pvc foamboard is about $60 from a sheet plastic supplier. You can cut it with standard woodworking tools, and it can be stapled to. It's also lighter weight. I would think 1/4" (6MM) thick would be plenty.

Here's some 3MM PVC foamboard formed with heat and used as a headliner. CLICK HERE

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Last edited by DanTwoLakes; 04-11-2012 at 11:14 AM.
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