Join Date: Feb 2006
Location: Annapolis, MD
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Starboard would be my first choice of material. Although it's very expensive it has all the right properties for the job. I have worked with Starboard for my boat and for special projects in cabinetmaking (that's what I do for a living). If you haven't used it before, make sure to get familiar with the unique properties, use the right screws and most importantly pre-drill properly.
You can use all your regular woodworking tools. I usually cut it on my CNC router and it works very nicely.
I am building some companionway doors for my IP and have bought a whole sheet for that project and have material on hand (although only in 3/4" sunshade, the Island Packet color) in case you would need a source for less than a 4x8 sheet .... ( I am not trying in any way to make a business out of it,just trying to help knowing how hard it can be sometimes to get less than a full sheet)
Let the forum know how your project turned out and what you decided to do.
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Island Packet 37 (hull53)