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stephen_h

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I need to replace our cockpit to saloon door. The present one is 28mm thick
made from two sheets of ply on a frame.

It would be nice to make the new one out of a plastic board that could be machined
to allow fitting of the door lock and a new window.

Any ideas?
 
I think you need something like Rigid PVC Sheet but Maybe there is something more appropriate in your country?
 
stephen_h said:
I need to replace our cockpit to saloon door. The present one is 28mm thick
made from two sheets of ply on a frame.

It would be nice to make the new one out of a plastic board that could be machined
to allow fitting of the door lock and a new window.

Any ideas?
Click to expand...

High density polyethylene (HDPE)

Its what is used for water and fuel tanks.

I have just usd some for a deck hatch where I need light but not see through.

Machine it with a router and TC bit.

You could also use perspex both clear and coloured I made some washboards from 10mm thick with a edging of an extra 10 mm making it 20mm thick on the edges.
 
After I dropped the original smoked perspex one-piece washboard down the companionway , breaking it, I got a new one made by a local plastics company. In the process I added vertical teak tracks to the sides of the companionway, where none existed previously, and got the replacement made up in two pieces duplicating the original ventilation holes and the holes for the lock and stainless steel handle.
It cost me the Euro equivalent of approximately £100, as far as I can remember.
 
The Stackpath looks like an interesting product but I am looking for
something that has a smooth surface finish and needs no maintenace.
 
Are you looking for a plastic sheet material 28mm thick? I think whatever you choose in that thickness is going to be very expensive. When I found out the cost of a sheet of 10mm smoked acrylic sheet I used 5mm instead and just doubled up the sides where it sat in channels. Worked well.
 
I am looking for 28 or 30mm thick. It is a hinged opening door with a mortice lock to be fitted into the 28mm thickness.
Could go down the wood route but hoping there might be something plastic I could use.
 
I have found a company in the Uk that supply King Starboard that looks like just the material I want,
all be it, a bit thinner than the original. A piece 600 x 1285 x 18mm thick is approx £225
cut and delivered.
 
The Vetus is interesting stuff but not structural, can't be painted and has a matt finish.
Also sheets are not large enough but thanks anyway :)
 
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