"Mike C" wrote in message
ups.com...
My Maxum 240SCR has had 2 cabin doors break in the last 2 yrs. The
first one I replaced with a stock door which was hard to find and
costs $500. I would like to make a new one The original is around
24x48 translucent bronze polycarbonate (as I understand it) and 3/8"
thick. What I am wondering is can I use white starboard in the same
thickness? Will it be strong enough? If I go thicker, the lock won't
fit properly (it sets on the top of the door and a cut-out).

I can probably find polycarbonate and cut that, but am afraid of
another breakage.


You might want to research "plexiglass" a bit. There are different types
(lexan, polycarbonite, etc. ) and they have different properties. One is
more resistant to cracking, but I've forgotten which one it was. I
replaced the flybridge "splash guard" on an old Uniflite several years ago
and I remember learning about the different types and properties of
plexiglass.
Maybe your doors are made of the wrong type for the purpose.

Eisboch