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Old 03-15-2014, 09:46 PM   #1
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Default 2400 SCR cabin door

My old acrylic cabin door had a gigantic crack down the middle of it and I needed to replace it. After some research I found a new one for $599.... Way too much!!! After contacting a couple of plastic places and getting some rediculous prices for one to be made, I decided to make one. I bought a piece of black king starboard and got to work. I removed all the hardware from old door and double-sided taped it to the king starboard. Made a rough cut around the outside perimeter with a jigsaw then put it on the router table with a flush-trim router bit. After I had my exact copy I drilled through the existing holes of the OLD door into the new door(exact hole placement for hinges, latches, etc). I separated the two doors and removed all the double-sided tape. Next I used a "round-over" bit to round out the edges of the door and had to make a few cuts where the lock mechanism fits... A little filing to the lock mech area and VOILA, new door!!!



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Old 03-16-2014, 04:13 AM   #2
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Nice job, how many hours did it take you?
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Old 03-16-2014, 04:49 AM   #3
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Thank you! It took about 2 hours total... The King Starboard is real easy to work with, it cuts and routers like wood.


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Old 08-25-2014, 03:02 PM   #4
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What was the thickness of the Starboard and did you use Starboard XL or regular?
Did you order online or get it locally?

Thanks in advance
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Old 08-25-2014, 04:39 PM   #5
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I bought it off ebay, not sure if it was XL or regular.... It is 3/8" thick. I would have went with a thicker piece but then the lock mechanism would not have fit.
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