[62 Overlander]

I'm rebuilding all of the cabinets in my 67 Caravel. They are really pretty simple. Like Ken said, I'd stick with 1/4" plywood for the panels. I'm doing the Caravel in knotty pine. Another idea I had tossed around would be to buy some wood veneer laminate. It looks just like formica except that the face is real wood. I've used it before and you can't tell that it is .035" thick once it is applied. You could take your old cabinet face frames, apply adhesive to the front and backside of the laminate, then apply the laminate and once it is dry come back with a laminate trimmer (or router) and route the openings. Then apply whatever finish. I didn't do it in the Caravel because knotty pine wasn't available in this type material. The stuff I used before had a honduras mahogany face. it stained and finished just like regular lumber, just have to be very careful not to sand through the veneer.