Thought I elaborate a little more on building the door since I didn't see much information around when I was looking for it. Perhaps I didn't find it but maybe it will help someone eventually
I had never worked with starboard prior to this and appears it's very similar to handling wood and I would venture to say it's actually easier. I was feeling a bit nervous at first with talks about it melting it etc. on the internet but once I made my first cut it was actually quite easy.
Was missing a few things of what I needed except for a hand saw and made a trip to the local HW store, obtained some files, clamps and a saw blade that King Starboard recommended. Definitely didn't want to make an investment for a single project so I tried to go the cheapest route I possibly could. King Starboard recommends somewhat lower RPM for cutting tools .. I watched this video -
but from my experience, the 5500rpm saw I had already (
http://www.sears.com/craftsman-18780-evolv-12-amp-corded-7-in/p-00918780000P) did the trick just fine. KS also recommends 60-80 tooth saw if I am not mistaken and so I had to purchase it for ~$10.
In order to obtain the Starboard material, after a trip to West Marine and looking at some sellers on-line etc, I ended up in a local marine upholstery shop. I just needed the piece to be in great shape since it's not going to go into a cabinet and both faces of it will be visible. Basically I wanted to see it and touch it before purchasing to avoid slow returns etc.
I was lucky to have one half of the door so I used it to exactly mirror the half I was going to build. So I traced the existing piece (it's a trapezoid not a rectangle!) onto the new piece and then used the old piece as a saw guide with the help of the clamps.
The resulting piece ended up being a rough cut and that's where the files came in. At first I tried doing it with a Dremel tool but that ended up being slow and I didn't like the results. The best results were form the hand file, used it without a handle just in the palm of my hand and took a very short time to get it to what I wanted. I started off with a more coarse file then finished with something more fine for the finish.
Used the OEM hinges which were ~$14 a piece (had to have the holes lined up with the existing piece) and these from
https://www.jamestowndistributors.com --
FSSMSFP832X3/8 MACH SCR FLAT PHIL S/S 8-32 x 3/8
FSSBN832 BARREL NUT S/S 8-32, 3/8" BARREL LENGTH 7/32 OUTSIDE DIAMETER UOM: bx-25
All in all couple of hours from start to finish and attention to detail.
for $12
