Angus- yes, takes me a while to hook on, BUT I found it eventually!!!!!!!!!!!!!!
J - I have used some of this PVC board (known in Australia as ‘Expanded PVC Board’ or ‘PVC Celuka Foam Board’) .
Pros are: I have found as the other guys have said, “it works just like wood” but without the grain and is perfect for Bream lures or other toothy fish as it does not suck up water when punctured- takes pint o.K., likes epoxy for ‘hangers’ and ‘screw eyes’ - it’s tougher than Cedar - I have satisfactorily laminated halves with ‘Plumbers Pipe Glue’.
Cons are: It is VERY buoyant and will need a lot more ‘ballast’ than usual, unless you are using it for ‘poppers’ (for which it is near perfect). If you use electric sanders it tends to ball up the surface which makes it hard to finish. Clear finishing (IMO) for toothy fish, needs to be a bit softer than hard epoxies as it tends to chip off.
An old friend of mine on here (‘Coley’) sent me some thin sheets to play with which is excellent as it has very small air cells (denser) and on small lures finishes near perfectly, the PVC I have found here is a bit coarser and harder to finish on small lures, but the size you are talking about would be no problem. It seems the thinner the sheet the denser the PVC is!!!!!!!
Where do you get it??? I am not sure where you live (it helps if you add your location in your 'profile') - BUT- go to your local plastic supplier (Perspex, lexan etc) and ask for Celuka board, or Sign Writers/ display type people, they use it to mount large photos for billboards - comes in 2.4 X 1.2 sheets @ 6 - 25mm thick.
I have a small amount of 18mm here, if you laminate 2 pieces and you get 36mm which should be wide enough for your purposes.
Send me min sizes and I will send you some pieces to try.
See it here: http://allstarplastics.com.au/pvc.htm
Pete