Stainless steel door panelI finally got a piece of suitable material to line the inside of the smoker door. It is SA240 stainless steel 1/16 inch thick. This is probably much thicker than necessary and adds a lot of weight to the door, but the price was right (free) so I can't be too picky about it.
Without the proper tools for the job I had to improvise and made a jig with some steel bars and clamps. Then I made my cuts with a side grinder using a thin blade. And yes, that is a ladder I'm using as a saw horse. It actually cut easily and only needed a little cleaning up with a hand file afterward.
Here is the test fitting of the door with only four screws holding it. I thought I was never going to get the holes drilled until I realized I needed to run the drill at a slow speed and use very little oil. I don't have any experience with stainless so I'm learning as I go.
Oh, you may have noticed in the above photo that the chimney has been installed. The outer shell of the box was not too bad to cut with the hole saw, but the inner liner which is enamel coated was considerably more difficult.