I need to make a shower door

[TQA]

The previous owner removed the door so I need to make a new one. This shower will only be used very occaisionaly as a shower as the boat has another much larger shower and loo I anticipate the door will be open and pinned back to the left of the opening for most of its life.

I want the door to open outwards and be flat against the bulkhead.

OK I move the door trims or stops to the inside. That should be easy.

Now what do I make the door from. I would either like to match the wood effect formica on the existing bulkhead or have somethink like a cream parchment as this is used on some other doors.

Bear in mind that the side that will be on view most of the time is the one that will get wet when the shower is used so it needs to be waterproof.

I am thinking of something that would be dimensionally stable water resistant or proof and about 1/4 or 3/8 thick. I would then add some trim strips to build the edges up to about one inch thick.

Any ideas on a suitable material. If push comes to shove how about 1/4 ply with a vinyl wallpaper and a coat of polyurethane?

Any hints tips leads or suggestions much appreciated.

BTW I am in St Thomas and heading east then south.

[tomwatt]

Maybe King Starboard? From what I read (haven't tried it so I can't swear) it sounds like it fits your circumstances.

[Zach]

If you do starboard, make sure you add a frame to one side to keep it from distorting. Great idea, but a lot of the ones I see warp over time at the top and bottom corners and are no longer flat. Make a template and use a router to machine it. Three cutting surfaces on the bit leave a cleaner finished cut than 2... Spiral is hit and miss on smoothness, sometimes they scallop. Either way you want to feed it about as fast as you can so the chips/waste takes the heat and not the part you care about. Go back and microbevel the edge with a 45 on each side... for a finished look. It'll be expensive, as you'll need a piece 3/4 or so thick not to sag over the height and width of the doorway, if you don't frame it in.

I'd go marine plywood, epoxy, and fiberglass... paying careful attention to fill the screw holes with epoxy and around the door hardware... but then again that fits the category of giving a man a hammer.

Zach

[TQA]

Maybe King Starboard? From what I read (haven't tried it so I can't swear) it sounds like it fits your circumstances.

Just had a look at the specs, that should do the trick nicely. Now I just need to find some in St Marten.

Thank you for the steer.