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I use 1/8" masonite for mine. Cut round holes to fasten the clips to the panel. Offset the holes to ensure the clips' offset is going in the hole correctly.
Mike
The X-Mat I initialy purchased was asphalt based and would run out in a vertical installation. After I discovered the problem I called Eastwood and found out they recalled all the original product. I had mine in the original boxes for 8-10 years before using it. Eastwood replaced the defective...
My upholstery guy uses closed cell foam sheet for his headliner installs. Insulation helps slow the solar gain in your vehicle. It is getting hotter each summer.
Mike
Sounds like you have found all the problems. Be careful with cleaning solvent, I took off the odometer numbers on my 65 speedo with brake cleaner. Lube that cable with a light grease. A little research should find a product recommended for such use.
Mike
Sure, you could also use small plastic plugs (hardware store), or cut small circles of black electrical tape and stick them on larger pieces, sticky sides together, which you place over the inside of the holes.
Mike
Jim Kramer probably still sells the correct patch panels to repair that issue, although I cut the top panel to use the OEM wiper penetration area as it wasn't quite the same. Probably the only option.
Mike