Consider Formica for cavity covers and pick guards. 4x8 sheets are as expensive as hell, but search Home Depot for "Formica Samples". 5"X7" pieces for 25 cents each....

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If there is a circuit board mfg shop near, ask them if you can have a few pieces of scrap laminate Boards are usually .062 fiberglass. Easy to cut and shape.

Dusty tho? 

In a factory, yep, but with the right tools, not bad. I have a little bench top shear, so sanding is minimum.

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