Ideally you'd have a door that is strong enough to be "people proof" for long enough for the entire passenger compartment to rush a dude, but not strong enough to survive the entire passenger compartment trying to get in and save the plane in this situation. Something that can survive a couple kicks but isn't a bank vault door. Pretty much a typical apartment door would be about right.
If they are outside trying to get into the cockpit, there may be time for passengers to react and neutralize them?
I very much disagree. Previously, an attacker could get to the cockpit by surprise and by suddenly overwhelming cabin crew. That is now much. much more difficult.
I disagree on this one. Bruce Schneier, who writes often, and passionately, on the ridicelousness of "security theater", cites doors (along with your your statement that passengers must resist) as having improved safety to a measurable degree.
But there isn't, sadly, an absolutely fix for every vulnerability. We can reduce the number of incidents and mitigate the risk, but some will always remain. It is the price one pays for such extraordinary freedoms and luxuries.
https://www.schneier.com/news/archives/2008/11/the_things_he...
Historically, hijackings are more deadly than rogue pilots. Neither one is a particularly big threat, but hijackings are the more important threat of the two. How many potential attacks from the past decade and a half got stopped in the planning stage because "Well gee, Bob, that sounds great, but how are we going to get into the cockpit?" While this stuff is rare, I bet it's not zero.
Beyond that, does not having a locked cockpit door actually save you from rogue pilots? I don't think so. There's a lot you can do to defeat other people when you're the only one belted in at the controls. A series of violent vertical maneuvers would suffice to defeat anyone trying to get back in. Imagine if, instead of locking the door, this guy had just pushed the nose over to negative two gees, then pulled up at positive three, repeat until everyone is dead? Or, pull the breakers for the higher-level fly-by-wire systems, point the nose at the ground, apply full throttle, and rip the wings off? The thinking seems to be that there was a calm 10 minutes or so in which he could have been stopped if only the door hadn't been in the way, but the only reason there was a calm 10 minutes was because the door was in the way.
Is this true? I can't remember a single other plane hijacking that resulted in the deaths of passengers outside of 9/11.
There were definitely a couple.
http://en.wikipedia.org/wiki/List_of_aircraft_hijackings
Lots of those were resolved without death, or with just a few deaths, but many others got lots of people killed.
As is the way of things, the current manifestations of asymmetric warfare can muddy up the discussion with modern-day politics, so please allow me to remind you that science fiction authors have been predicting the rise of it since at least the 1980s, just due to the ever-rising destructive power any one individual can wield. Who or what cause happens to pick it up is an accident of history, but you can be guaranteed someone will try. This is an incentive structure that those of us on the side of civilization are going to be doing continuous battle with for a long time.