tony, whenever you get around to it. im looking at starting some time next week though.
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1/8 and 1/4 Landau foam would work for your needs. Check a shop in your area that works on vinyl tops.
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tracy, thanks for your input. i'll give them a visit and see what they have. will those foams be hard enough to use with a router? im finding this in 1/8 and 1/4" rolls so im thinking its going to be too soft for a router. how would i get a nice uniform edge that rolls into the cut out section?
depending on what i end up doing with the mdf, ive found that my 3 main trunk panels would weigh between 8 and 12 pounds total. not extremely light, but ive taken a lot of weight out. the 12 pounds would be with 1/2" frame and 1/4" inlay.