I plan to use a butane burner in this boiler. One of the common ways to light these is to turn on the gas and put the match at the top of the chimney and hope you retain most of your eyebrows and that the resultant pop-back does not extinguish the burner. I was looking for a better way so I thought why not a door?
Since it will be painted, I am making it out of aluminium. Here is a shot on the mill whilst cutting the 1.5" radius so that it fits the boiler shell.
Here is is transferred to the small mill to cut all the bits that don't look like a firebox door.
Here we have just finished cutting out the centre and the two bosses that will be the top and bottom hinges.