G’day.

Any suggestions for card to make new door boards and pocket trim. Would prefer as close to the original as possible. Cheers.

If you aren't too keen on making them yourself there are ready-made versions available. In any case the thickness and material is mentioned in the advert.

https://www.ebay.com.au/itm/Australian- ... 1438.l2649

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ex-NSW Police 1970 MK II Cooper S
VMCI #43

3mm plywood from Bunnings works for me

From a 1966 mini: the original 'masonite' looking door cards are 2.8mm; the rear quarters are a red coloured fibreboard looking material about 2mm.
The best I could find at the time was MDF coated in Bondcrete for waterproofing (don't know if it will work) but MDF is 3.3mm and was a very tight fit in the top retaining mould.
Also had to carefully cut away the vinyl along the heat seams as it sticks to the board. Replace the original wadding with polyester wadding from Spotlight.
The business winabbey has listed would be a helpful alternative. I'd consider the 2.8 option too.
If I ever do this again, I would also consider the plywood.

If I was ever going to do this, I'd be using the ones from Australian Door Cards on ebay.