Well today I bought some kitchen cutting board $9.90. I cut 10 pieces about 65mm x 50mm. Board is just about 5mm thick. Tried to find the thicker ones but no chance. Once I stacked 5 - gave me 35mm extra bump stop, resulting in 3" gap in bump stop, which should be OK.
The trick is after stacking the 5 layers, I then drill 8.5mm holes while cramped together. Then temporarily bolt the 5 layers and use an angle grinder to smooth out and square it nice and neat. The angle grinder actually melts the plastic slightly and turns it into one solid block (almost any way) Used 60mm long high tensile M8 Bolts and all is done. Now need to ramp it and check.
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