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there isn't really any method, to achieve car panel sized plugs from scratch, that is cheaper that wooden framing filled with foam. sure this could easily cost some thousands, but we are talking about a car. building one yourself usually means lifetime objective. if you are not willing to spend around 2500€ (wich would be really, really cheap) for plugs and materials for the panels, I would recommend not do it. and 2500 is my estimation of the cheapest possible way an experienced worker could do it, without buying tools, using carbon or sandwich cores, or even advanced processes. if you want to learn something about wood/foam plug making, search yt for "easycomposites air box". just use some wood panels, instead of the harder foam, they are using.
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