Polycarbonate! It's so good, and we use it a lot on my FRC team. Polycarb is generally expensive but is high quality. Acrylic will do just the same, for cheaper, but is a bit less forgiving when cutting it. Cutting acrylic with a band saw is difficult as it will tend to melt, so i end up using a dremel tool with something akin to a mill bit. At first it was difficult to manuever, but after playing around with some scrap, I got fairly decent with it. To protect both sides of your project, all you need to do is cut out another piece, mount that with bolts above all your electronics and other stuff. If you are looking to heat form as well, acrylic is easily formed (Never tried polycarb...)
Would this work for you?