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Manila folders work great for over shot cards. Three ring binder covers will make great over powder hard cards. 1/2" Celotex board makes fine cushion wads.
Place of employment in mid 90s used to run diazo prints for our projects. We bought paper by the pallets, 24x36 and 30x42. Each packet had two sheets of "cardboard" enclosed, one top, one bottom, similar to the backing of a pad of paper. I brought home scads of them to punch out over-powder card wads for BPCR, no reason you couldn't glue together for whatever purpose and thickness you need.