"Mike C" wrote in message
oups.com...
On Apr 30, 5:26 pm, "JimH" wrote:
"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.

The starboard will most likely work but you will lose the light the
translucent door lets into the cabin. It will also show dirt much more
than
the poly.

Why are the doors breaking? I think you have to focus on this problem
first.........the poly cabin door should not break as you are
experiencing.

My guess as to why the doors are breaking is the lock cut-out. The
door is essentially a rectangle with a rectangular cut-out on the top
middle of the door. The cutout is maybe 4x2 inches. I think this cut
out wekanes the whole door. Both times it has broken from the edge of
the lock cut-out.


Round the corners of the cut out to relieve stress concentration. Also, you
could do it in Lexan, same stuff around hockey rinks. Take the measurements
to Tap Plastic or another plastic shop and they will cut it to size. No, or
very little charge for the cutting.