🛠️BUILD a CUSTOM Front Casting Deck | DORA PROJECT 🧜‍♀️

📖 Dora the Quintrex Explorer gets a custom aluminium deck! It's time to ditch that old, weak, heavy plywood deck for a LIGHT🪁, STRONG 💪 and BETTER✅ casting deck.

After my year of use with the old wooden deck, I could feel the timber starting to sag, and the carpet and adhesive was starting to come away from the timber.

Beyond the visual and structural issues, the deck had a very small opening to store things underneath, it was nearly impossible to remove.

The solution was to totally replace the old deck, with a brand new, custom casting deck. The new deck was constructed from 4 main components. An aluminium extrusion frame, a sheet metal deck, a piano hinge and a latch.

The frame was TIG welded together, with the sheet metal deck secured to the frame via rivnuts (nutserts). With the rivnuts secured to the panels, it's possible to tighten them from the inside of the frame ensuring that no hardware could be trapped underneath carpet, or EVA Foam (Seadek).

The deck took a couple weekends to finish, especially considering I had to learn how to weld.

⌚TIMESTAMPS⌚
0:00 - Introduction
0:28 - How we'll do it
0:52 - Removing Rear Deck
2:12 - Frame Planning & Building
3:00 - Hatch Truss Support
3:12 - More Frame Building
3:38 - Installing Piano Hinge
4:50 - Installing Latch
5:42 - Installing Frame into Boat
6:20 - Template and Cutting Deck Panels
7:37 - Installing Deck Panels
8:07 - FINISHED! Cost Price

The DORA Project follows the build process of converting a very bare Quintrex 385 Explorer, into a very well equipped fishing boat, dedicated to light tackle fishing.

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