DIY door panel material options

[ibike]

Working on the interior of my DIY build and getting to the point of building the door panels for the side and rear barn door panels. It seems like most folks are using upholstered plywood but I’m wondering if there are any alternatives.

I’m specifically looking at ABS plastic or HDPE/Starboard, either 1/4” or 3/8”. It’s hydrophobic, anti-microbial and is easy to cut and join with regular woodworking tools.

Just wondering if anyone had tried something similar before.

[mgmetalworks]

ABS works good. I use it all the time for paneling. In my experience with Starboard, it doesn't take adhesive very well. it's a nice product and easy to work with if you leave it raw.

[BenJJ]

I used 1/4" marine grade HDPE for my cabinets and have been very happy with its performance. Looks nice and cleans up really easily.

https://www.sportsmobileforum.com/fo...ets-26866.html

[Wisco150]

I’m working on a removable molle style door panel out of aluminum. I’ve never worked with ABS but a similar style might work out of ABS?

[ibike]

Originally Posted by BenJJ

I used 1/4" marine grade HDPE for my cabinets and have been very happy with its performance. Looks nice and cleans up really easily.

https://www.sportsmobileforum.com/fo...ets-26866.html

That looks awesome, thanks for sharing.

[ibike]

Originally Posted by mgmetalworks

ABS works good. I use it all the time for paneling. In my experience with Starboard, it doesn't take adhesive very well. it's a nice product and easy to work with if you leave it raw.

Good to know about the adhesive, I plan on using black starboard and leaving it raw. I'm also planning on using it to make cubbies for inside the door cavities. Not sure if plastic welding, pocket screws or both are the way to go for attaching panels to each other.

[Scalf77]

I used 3M's Scotch-Weld DP-8005 when making a short back splash for my counter top. Starboard also recommends Lord 7542-AB, or Chem-Set™ 6105 Polyolefin Bonder.

-greg