first deck extension, a few questions

[stumpjumper1]

ok, so you guys convinced me to build my own deck extension on my '03 champ 203. i've got it planned out in my head exactly how i want it to look, but i just have a few questions before i get started:

what lumber should i use for the frame? as far as the frame crossbraces, should i be concerned about it swelling and damaging the boat's fiberglass where it will sit between the rod lockers?

should i use all staineless screws and hardware?

what hinges should i use for the lids?

what paint should i use to seal everything?

thanks guys!

[ranger230v]

If it were me, I would not paint the wood, I would seal it with epoxy resin, twice. For the plywood deck, dont use pressure treated wood, I would lam it with one layer of 6oz cloth. The reason is even plywood that has been sealed, will start to surface check over time. Once that starts, then water intrusion will follow. A thin layer of cloth will prevent that. Yes on all stainless hardware, galvenized will eventually rust. Dont know how your going to do the lids but stainless piano hinge is a good choice if it will work.

Be sure and post some pics of the progress.

As far as how you go about this project, its really comes down to personality and what your expectations are for the finished product. Some people are short on time, money, and patience. Having something last as long as possible is not a top priority. I am a detail tweaker, I overdo everything. "Perfection is the enemy of good" . My point is theres different ways to go about this, pick one that you think you can do and go for it.

[haveme1]

To glass it would increase the strength but not the weight. You could make it using cardboard form and fiberglass.

[southsidecustoms]

I made mine out of slum. With an slum plate. Square tubing. Welded the frame and rivoted the plate. Then covered it with little foam and carpet. No hinges. Works good looks good.

[stumpjumper1]

i think i'm gonna build mine as a frame only, out of 2x4's, then use 3/4" plywood for the back end and lid. i can't see building a box inside, that would be a waste of effort.

[haulingbass]