Custom Snapdeck for Xtracycle Cargo Bike

My Xtracycle needed a new "snap deck", which is the flat carrying area above the rear tire.  I wanted something a little more distinctive than the stock deck, and also wanted to try a longer deck. 

I started by doing some "CAD" - Cardboard Assisted Design, that is. I made a few sample decks using some cardboard, and trimmed them until I found a size and shape I liked. 

I considered cutting the deck out on the bandsaw or with a hand-held jigsaw, but decided I wasn't steady enough to pull that off. Besides, I have access to TechShop's Shopbot, and it's way more steady than I am. 

I sketched the desgn in cardboard, and test fitted a few ideas. 

Once I settled on a design, I translated it into the computer version of CAD, and then created the shopbot file from that.

Shown here is the test piece made from scrap plywood. 

The piece of Brazilian Cherry I bought for this project was too narrow, so I split it down the center and inserted a 1.5" wide piece of maple for contrast.  I used a biscuit joiner to hold it all together - there are several Instructables available showing this technique.

Once the piece was dry I ran it thru the planer until it was clean and flat, then ran my shopbot file on it. 

I wanted to add some zazz to the edges, so I used the table router and a small rounded bit to cut a groove in the edges.  Eventually I hope to install some red ElectroLuminescent wire in the groove. 

I used Formby's Tung oil t o seal the deck.  I applied about 5 coats to each side and let it dry for 8-12 hours between coats. 

Using blue masking tape I marked where the hold down hooks needed to be located.

Using the old snapdeck as  template, i marked where to drill the holes. I drilled the appropriate size holes and then used a countersink bit to recess the screws.

Install the Superhooks and tighten them down.

Now, go for a ride.