>>This sounds like a great idea,
Tom,
I have only done this with 4'x2' cages made from 3/4" plywood. I'm sure it will work with 4'x3' cages made from 1/2", but take care that the cage is strong structurally on it's own.
Expanded PVC or any plastic sheet product is not always best to buy online. San Diego Plastics, Tap Plastics, and US Plastic all carry it.
Shipping is very expensive and only adds up to money saved if you buy several sheets. Not knowing how many cages you're going to build I'm guessing you're better of looking locally.
Start with plastic distributors or fabricators in your area and ask for expanded PVC or Sintra. I found it at a plastic fabrication shop that specialized in building acrylic podiums and displays.
If that fails or the drive is too far I'd recommend calling local sign shops. In that case you should ask for Sintra, not expanded PVC. The sign industry pretty much calls all expanded PVC products Sintra. Sort of like asking for plexiglass and getting generic acrylic.
Only then should you start considering an online purchase. Or if you do plan on a large order.
Just a quick tip.
Since Sintra is not exactly cheap you might consider making your cages 48"x32" instead of 48"x36". By leaving out those 4" you can cut a full three bottoms from a full sheet.
On the same note, the outside dimensions need to be 48"x32" so you can overlap the entire rim of the cage with the Sintra. Make sure you account for that up front.
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Current snakes:
0.2 Gonyosoma oxycephala - (Silver/Yellow)
3.3 Gonyosoma oxycephala - (Green)
2.1 Gonyosoma janseni - (Black)
3.3 Gonyosoma janseni - (Black & Tan)