So - we bought an Aerolite Cub 160 new in 2008. We've now replaced both bunk doors at a cost of about $1500 each. The originals are crap. I've seen another model the exact same as ours and both ends are also de-laminating. When it happened the first time I tried to fix and restore it (back bed). Unfortunately I didn't have the work space to really work on it so after taking it off and ripping it apart as much as I could I caved and ordered a new one. I can tell you the new ones are made a hell of a lot better than the original. I did everything I could to avoid having the same problem with the front bunk. Didn't matter - I caulked and recaulked and still it rotted. The biggest problem is that that it is not sealed properly when it was constructed and the plywood used is a very thin mahogany luan plywood that acts like a sponge when any water gets in - and it will. now I'm torn between getting rid of it while the bunks are in good shape or stretch it out and try to get my money back by using it for a few more years. I took lots of pictures while taking the door apart and I would prefer to email them to you directly but if i can't and you really want them I will see what I can do. Check out
Bill Patterson's series on Youtubeof him replacing the door - you might learn something and it might encourage you - good luck