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Well, I build furniture and built-ins so I can't say that I have any expertise in auto interiors.
I would recommend maybe just veneering some thin ply to get the look you want in something that is 1/8". Then you could do a burl or birdseye. Not cheap but I think those grain patterns are nice for interiors since they don't have a "direction". Look for marine and aircraft suppliers for thin ply. There is also Italian bending poplar ply but its wiggly as you might have guessed. And I think Baltic birch ply can be had in pretty thin sheets. I know I've gotten it in 5/32" before.
I haven't ever had a need for faced ply that thin, if its that thin its usually just a bending or lamination core type ply. As for the edges as long as you use a heavy finish you should be alright but I think some kind of trim would be nice. Vinyl or bright metal. UV protection important too for the finish.
This is a driver, right? The durability of the panel is something to consider. I'm thinking how often shoes come in contact with the bottom half of door panels. Maybe top part wood with vinyl below. Just use the wood for visual interest the way Volvo used the embossed pattern. That way you would just be stretching flat vinyl which would be pretty easy.
The thing with the Amazon interior is that it has a spartan appeal. There just ain't a whole lot of fluff. All business.
So I have a hard time figuring out how to use wood accent without it just being "too much". I think a nice wood steering wheel and shift knob is a good place to start for me. I want to build a console so I thought I might add some wooden accents on that.
Its the exterior that I was thinking would be such a big project. Interior is just patterns and attachment points. Besides the actual aesthetic aspect that is.
Feel free to e-mail me if you want to kick this can some more.
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