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Hi Paul,
I got my threaded inserts from Hills clearance centre in Victoria. They are the same company that makes Hills hoists etc. I am sure they would have a similar shop in Sydney. I am not sure which wall thickness they suit so it would be best to get the inserts first and then find the tubes to match.
I prefer thin ply to plastic. You can get it in 1.5 mm thickness and it bends easily. It is light, strong and doesn't distort in the heat. I got mine from a marine timber supplier. Doorskin might be an alternative. If you want Black plastic though, try an art supply shop. The plastic folders they supply for storing artwork look very much like kydex to me.
Rod.
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