For what it's worth for other guys out there wondering the same question i did I used #3 cross link foam for the sculpting. I wish more trimmers would share to their fellow friends on here . And thanks tou all of you that take time to post the tutorials.

Your door panels look incredible, thanks for sharing the info!!

Those look awesome!! One question , what did you use to attach the panel to the door?

I use plastic xmas tree type fasteners. Panels are double layer pvc so the heads are not visible when the panel is attached

Thanks for posting guys. I had the same question!

Seen this late. Assuming it was closed cell foam sanded to shape. I love using PVC board, has a million different names but i use it all the time for marine applications that don't need heavy support/Structure. If it does need structure I'll use Starboard(marine use for 1/2", its expensive and heavy, but 1/4" with torch or Marine Heat shrink flame thrower can be molded in shapes like ABS plastic). You should think about using heavy duty magnets for inserts on the door panels. Not the initial fastner to door panel tho.

Where are you finding PVC board. My suppliers don't carry it. They say that people were having issues with glue letting loose.

I buy mine from Fargo Plastics. Any of the larger plastic suppliers would carry it McMaster Carr has it but you will pay a premium there. As far as turning loose as long as you sand it (80 grit) and use Weldwood landau adhesive you won’t have a problem. Make sure you sand your foam before bonding too.