When you think of classic car restoration, your mind likely turns to hand-shaped sheet metal, chrome trim, or carefully matched paintwork. But hidden beneath those surfaces, another material plays a surprisingly important role—plywood.
Though often overlooked, plywood is a practical component in restoring classic cars in Australia and overseas, especially for interiors and fabrication aids. From mid-century UK-made sports cars to pre-war American wagons, plywood has earned its place in the restorer’s toolkit.
But let’s be very clear: plywood is not a substitute for hardwood and steel where it doesn’t belong. Its use should be thoughtful, 100% accurate to the original design, and properly sealed to ensure strength. For structural frame repair plywood is not used at all —it lacks the torsional strength and crash resistance required for safety. Without being sealed properly unprotected plywood will absorb moisture and degrade quickly.
Let’s explore where and how plywood is used in the one of the most sophisticated industries.
Functional Roles of Plywood in Classic Car Restoration
Interior Panels and Trim Backing
Thin plywood (usually 3-6 mm) is ideal for:
- Door cards
- Kick panels
- Trunk liners
- Seat backs
- Speaker mounting boards
Why not fibreboard, like in some original builds? Because plywood is more stable, resists moisture better, and holds upholstery staples and fasteners more reliably. A lot of restorers often choose Birch or marine-grade plywood for long-lasting results.
Floorboards and Underbody Sections
Some older cars (for example, British models) used plywood as part of their original floor structure. While this would be frowned upon in a modern chassis, when replicating non-load-bearing floorboards in pre-1950s cars, sealed marine plywood is both period-correct and durable.
Forming Jigs, Molds, and Templates
In custom fabrication, plywood is often used to create templates for shaping complex body curves or replicating interior geometry. This is particularly valuable when original parts are missing or when crafting one-off components for coach-built vehicles or hot rods.
Upholstery Structures and Seat Backs
Many classic car seats, especially in older American and European vehicles, featured plywood bases or backs. When reupholstering, restorers mainly replace these with fresh panels cut to shape and sealed to reduce delamination over time.
Classic Cars That Used Plywood in Their Original Build
We prepared a list of classic cars where plywood was the part of the original construction.
American “Woodie” Wagons (1930s–1950s)
- 1941 Ford Super Deluxe Woody Wagon
- 1948 Chrysler Town & Country
- Chevrolet Fleetline Woody
These cars combined both real hardwood framing and industrial plywood—not just decorative only, but as part of the vehicle body. The plywood was structural in a sense, forming the outer "skin" of the wooden body. Side body panels were made of veneered plywood, framed with hardwood (typically ash or maple).
Morgan Motor Cars (Early 20th century – Present)
- Morgan 4/4
- Morgan Plus 4
- Morgan Plus 8
The wooden frame carries the aluminium bodywork—plywood is secondary but original and intentional in factory design. Marine-grade plywood is still used in modern Morgans for structural panels under seats and for the floor. Morgan cars famously use a hand-assembled ash wood frame, but plywood floorboards and interior panels are used throughout.
MG T-Series (1936–1955)
- MG TA, TB, TC, TD, TF
While the main body tub is metal over a steel chassis, plywood was factory-installed in non-structural interior elements. Used in floorboards, interior side panels, and seat backings.
Bentley and Rolls-Royce (1920s–1950s)
- Rolls-Royce Silver Dawn
- Bentley R-Type
Never structural—only interior design and luxury paneling. Interior trim panels were crafted from veneered plywood (walnut, mahogany, etc.). Some boot/trunk liners and rear interior panels were backed with thin plywood for rigidity and elegance.
Volkswagen Beetle (Pre-1970s)
- Volkswagen Type 1 “Beetle”
The main body is entirely steel, and plywood was only used in interior trim. Original door cards and trunk linings used hardboard or thin plywood, depending on the trim level and era. In restoration, these are often replaced with higher-quality plywood for longevity.
The DIY Cars of the 1950s
In the 1950s, in the Eastern Europe plywood coated with linseed oil or veneered using casein glue became a key material for DIY automotive construction. It was widely used for body panels due to its availability, ease of shaping, and reasonable structural strength. For frames or space-frame structures, builders often used whatever materials they had on hand—steel angle sections, C-channels, offcuts of plumbing pipe, and various types of scrap metal.
Despite the improvised nature of these builds, the resulting vehicles were surprisingly resistant to corrosion. This was partly due to the reuse of already oxidised or oil-treated metals, and partly thanks to the protective properties of linseed-treated plywood. As a result, many of these home-built cars achieved a level of durability that was unexpected for the time.