Side panel material ???

Same, there Artic white definitely matches perfectly. The few things I have re-done in the cockpit, I have used their artic white and it looks great that's for sure.

I also found this: https://www.eplastics.com/ They have a lot offerings as well.

Looks like some samples and testing over the next month.
 
I’m doing the same project now,
 

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John, one little caveat to be aware of with starboard and both your's and Orlando's location is the temperature swing. In no way can I recall the exact data/measurements here, but HDPE expands and contracts more with temperature than PVC. Because of that, long lengths of HDPE usually need to have the screw holes enlarged to allow for the expansion and contraction.

With your 9' length issue... just thinking outloud here... probably something to experiment with... since the PVC products can be glued together with PVC cement, I wonder if you could edge glue two pieces and then fill the gap with a glue/PVC dust mixture like you would with wood. Possibly create a small v-notch then fill and sand smooth. Again, never tried it - but it might be worthwhile to play around with it.
 
John, one little caveat to be aware of with starboard and both your's and Orlando's location is the temperature swing. In no way can I recall the exact data/measurements here, but HDPE expands and contracts more with temperature than PVC. Because of that, long lengths of HDPE usually need to have the screw holes enlarged to allow for the expansion and contraction.

With your 9' length issue... just thinking outloud here... probably something to experiment with... since the PVC products can be glued together with PVC cement, I wonder if you could edge glue two pieces and then fill the gap with a glue/PVC dust mixture like you would with wood. Possibly create a small v-notch then fill and sand smooth. Again, never tried it - but it might be worthwhile to play around with it.

Dennis, you beat me to it. PVC has to be planned a little more than wood for thermal expansion (and probably Starboard as well). We have a 35’ x 10” PVC fascia board across the front of our garage made from two pieces that are glued and the joint is invisible. That said, although the joint does not show, during the winter there is a notable gap at the ends. While PVC pipe glue will work, the purple color is kind of hard to work with. But there is both a pvc adhesive and caulking. The glue holds stuff together and the caulking is elastic enough to compensate for thermal expansion.

So if you are doing a winter project with either of these products, leave some room for expansion in summer time temps.
 
I’ve posted this on the Classic forum for the 300’s. I decided to use 3/8’s Birch. I used the old panels as templates. I made some mistakes, learned from them and got the cutouts the way I wanted them. As you can see the back areas were close to worthless so I used glass with LEDs. The front storage areas have Vinyl Headliner. Once everything is sized the new screws are put in place and counter sunk. The ends have to be bent to tie in with the back, that was a little tricky. I used glass resin on the backside to prevent water issues. The front has a mahogany veneer and used a router to round the edges and trim the edges. Then several coats of Spar Varnish

I’d give you the same advise others gave me.....Take Your Time!
 
Henry - yeah, that purple primer would certainly add a twist of color to the project! Luckily, though, clear primer is still available.
 

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