As my 95 has a door card missing and a rear (2nd row) side panel that has been hacked about, I'm thinking about making a set of customs ones. I've read elsewhere about 3mm Foamex sheet being used for door cards, and I'm considering getting this covered with a non-standard fabric.
Before I commit to buying materials, just though I'd ask whether anyone have experience with Foamex, or similar materials?
I have used Foamex as an alternative to plywood for applicatios where it would get wet and wood would suffer. I would say it would be a suitable alternative to the hardboard originals. I don't think it is as flexible as hardboard if that is an issue, but it is easy to drill and cut. A water jet company may be able to copy the pattern for you. The foam core means that you can't really rivet to it, it is less dense than hardboard.
I have used 3mm hardboard from B&Q they will cut one sheet into 3 pieces so you can play with one to get the right shape. The holes for the clips need sanding on the edges as the original board is thinner.Secure the fabric with glue hold in place with clamps. Ian