hey twinchy... i spent about a total of 60 hours making those door panels... i don't really have any more pics, they got deleted, but here's another long distance one:
oh and underground... i've had some experience cutting that stuff with a jigsaw!
do you find that the edges crack a little when you cut it as well? i had to be carefull to not get too big of a crack in it when i was cutting cause i had limited amounts of it... anyways about it melting back together, i couldn't find anyways to avoid it, so i'd do after cutting it, i would just snap it off

leaves rough edges though, so if you have access to a spindle sander that would work great for those curves you're making...