Re: New K5 parts coming soon!
 

Yep Luan. Def has to be sealed or painted prior to being covered. Marine ply is $65 a sheet vs $20 a sheet here. It would have pushed price up too high for the finished product. Luan far more stable than the pressboard GM used on originals.
Marine ply still needs to sealed as well. Wood that stays wet will just rot. Seal it and keep it dry, lasts forever.

The gap over wheel well is allowance of carpet on the tub and the roll over of whatever upholstery is on the panel, just as GM did. Not an inch, more like 1/2". Panel wasn't screwed in so it may look bigger than it really is.
These were made using NOS panel as the template so they are spot on for fitment.

All moot anyways as don't think I'm making anymore.
Thanks for asking though.

Re: New K5 parts coming soon!
 

Thanks for that great answer! Too bad you aren't going to make them but I imagine shipping would be a nightmare!

I still need to check my rear sill plate. Those look awesome, although I'll never figure out how you make'em. Looks complicated to say the least.

Thanks for the reply.

Re: New K5 parts coming soon!
 

Actually shipping isn't bad. Around $35-39 to east coast. Its only 1" thick so works in favor with Fedex.
Sill plates are a PITA to make to honest. The bends aren't bad. It's the radius that's hard. Plus you need to do it in order. Bends? Radius? Arrrghh.
I have a skid of aluminum strips I'll make you a deal on...

Re: New K5 parts coming soon!
 

PM me details. Ever thought of selling patterns for the sides? Might be a good idea if you have a way to print something that large.

Re: New K5 parts coming soon!
 

Pattern idea passed thru my head but then what if they cut it wrong and blame the print out. Not into that.
Plus by time you get the ply, trace, cut and finish the time spent is what I was charging.
And this way I control final product and fit. ;)
Im playing with a new metal version that has storage compartments for the hardcore adventure guys. Not ton of room inside there but more than enough for tow straps, cables, small tool collection etc..

The skid of strips comment was in reference to the screwed R&D trim plates. Going to recycle.