We used 1/2" MDF, and had to do some bonding of multiple panels to then remove material to get the bends. For the 45 degree routing around the handles, etc--we bonded two panels for that section only to cut down on weight. Most of the existing Traverse structure was 1/2" and we matched that when we used the birch ply on structure. We removed the back of the vans wood structure (supporting bed) and fab'd metal/welded supports, which gave more room over two Frontrunnner sliding pullouts.
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