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ive used pine befor, infact ive used balsa wood. works just fine. as for those clearance issues, ive found that the best thing to do is to make the car 2x as tall as you think it should be, this way you will be able to cut it to the correct height and it will allow you more material to play with when mounting it. so basically just extending the base... i have also used bondo. this also works good, just make sure you have it to where you want it. i found its easiest to find imperfections if i sprayed a very light layer of whte or gray paint... helps me smooth it out a bit more.. what thickness plastic were you thinking about using?
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