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Old 04-03-2013   #21
cataraftgirl's Avatar
Sandy, Utah
Paddling Since: 1997
Join Date: Jun 2009
Posts: 3,121
That looks great. Did you do the cuts yourself? Nice work!

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Old 04-03-2013   #22
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Whitefish, Montana
Paddling Since: 2009
Join Date: Jan 2013
Posts: 20
I did. Thank you! Super easy to work with too. It’s a little heavy... But at least I won’t have to deal with maintenance issues.

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Old 04-03-2013   #23
Beaverton, Oregon
Paddling Since: 2005
Join Date: Jun 2010
Posts: 569
I got my Al diamond plate side decks, trimmed to rough size at White City Metals outside of Medford, OR. I think I paid about $120 for both sides, which are something like 9' x 22". I have no idea if they ship.
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Old 04-03-2013   #24
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Flagstaff, Arizona
Paddling Since: 1993
Join Date: Mar 2009
Posts: 57
You can't beat aluminum.

If you don't have any plans to change where your crossbars meet the side rails make a permanent piece of decking out of 1/8" 3003 aluminum diamond plate. The 1/8" material alone isn't strong enough to span the gaps between the crossbars but if you take it to a machine shop and bend a 1 1/2" lip along the edges it will be. If you want a side deck that is 9" wide and 6' long you'd need a piece of aluminum 12" wide and 6' 3" long. Before you take it to the shop you'll need to cut out slots along the lip where the crossbars are located and cut clearances for the lopro's or frame fittings. You'll also need to cut some holes with a hole saw where you attach the frame to the boat etc... You can use a carbide blade in a table saw or circular saw for straight cuts. A jigsaw or router will work for rounded cuts. I've made a router jig for making uniform slots for 1" webbing where I want to mount 50 mm boxes and for attaching the decking to the frame. Once everything is cut, filed and smooth take it to your local machine shop and have them bend that 1 1/2" lip around the edge. You'll need half a sheet of diamond plate for two decks; a whole sheet costs about $200. The machine shop should be able to do the 8 bends for $40. This could be knocked down to just 4 bends if you just did the sides and omitted the front and back. When you're done, you'll have a zero maintenance deck that looks fantastic. If you don't have the tools or skills the machine shop can do the whole thing.

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