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What thickness of Plasticard should I use for scratch building a Warhound Titan?

1 or 2mm thick plasticard is usually the best for scratchbuild construction as its quite rigid in the sizes typically used for 28mm models and still easy to cut. However if you're building something the size of a titan, you might need to consider some kind of internal structure to stiffen the larger plates, or you could just stick together multiple layers of thinner card.

For something the size of a warhound you'll want some strength sideways, I'd go with 2mm thick plates there.

I'd recommend calculating a reasonable estimate for the material used before you commit to it. For regular SM tank size stuff, it's most of the time not cost effecitve to make it yourself.

As Finty said, you should consider building the overall structure - it's skeleton - from something else. Take a walk though the big box DIY store and check out all the yummy and hilariously cheap plastic they have ready for electric installation and plumbing. I'm not saying your titan should look at home under a sink, but consider the round and square shapes in the warhound chassis and what your hobby saw can do to those home improvement bits. =]

Hey I'm currently using 0.75mm thick Plastikard to build mine it's holding up very well good strength to it and easy to work with.

Iv never made a titan my self, but I have access to 4mm styrene plastic card which is nice for internal support,

probably use thinner card for rounded shapes.

I haven't build a titan sized model from plasticard. The largest one i build was a baneblade using 2mm plasticard. It it rather sturdy so with internal supports 2mm would probably be good for a titan. 1mm would also work i'd think but you need some more internal structure. Also what does add a lot to stability is additional details like armor plating. This serves two purposes - additional stability and more details. For that you can use 1mm or thinner plasticard.

And addressing the costs:
I don't know how expensive plasticard is in your area but the sheets i ordered(0,5mm, 1mm and 2 mm - 2 sheets for each size) wheren't too expensive. Depending on how much additional layers of details you plan to add you could probably build 2 or 3 tanks for the price of one. I had enough material for 2 rhinos and a baneblade and it costs me around 1 and a half rhino kit. And i still had a lot of leftovers from the thinner sheets.
The big problem comes with the time it takes. And don't forget the addional bits you might want to use if you don't like building everything from scratch.

Well, I think I'm going to need about 13 or so sheets, which I'll probably get off of eBay, and that's not including details, of which I can probably summon mostly from my bitz box.
But I have tons of free time, so that won't really matter.

If you can get hold of larger sheets use them. You'll spent less for the same amount. The sheets i ordered where 100 cm x 50 cm or something like that. I got them from a architect web shop. And they even had larger ones.