Thanks for the compliments. I'm in the process of helping a friend build 3 more for his room.....which is where all of my chondros are at right now.
Don't expect the guys at HD to help you. Most really don't have a clue when it comes to building or construction. You might also try a local millwork or cabinet shop. HD and Lowe's do no carry black melamine and it's like talking to a wall about ordering the right stuff from them.
Some cabinet shops will cut your materials for a small fee and they will be perfect cuts. You could ask them about assembling the cage as well and adding the other items yourself later on.
Depending on the market price, black melamine runs $45-60 per sheet, where white is around $32-45 per sheet.
These cages take very little time to put together. I would estimate from start to finish, about 1 hour per cage....if all of your cuts are made before hand. They are surprisingly simple build. It's easier to have them cut it for you because of the weight. A 4x8 sheet of 3/4" melamine weighs around 75lbs....which in my opinion is the only downfall of melamine. I've sprayed and sprayed these cages, and as long as they are sealed properly, you shouldn't have to worry about warping.