A piece of cardboard was used to determine the shape of the bench top as well as the pattern to cut out the top from a single piece of 1/2 inch plywood. After finish trimming the ply and rounding the edges to prevent abrading the vinyl upon covering, I built the under support out of 2x3's (2x4's would have been serious overkill) and legs from more 1/2 inch ply. The bench was designed with a third leg, however, upon final assembly the whole structure was so strong, it was not necessary. This worked out great since it opens the whole area up for storage. After a trial assembly, the structure was painted with a couple coats of enamel then off to the upholstery shop. The guy charged me $175 to cover it. He not only matched the curve in the bench but given measurements, was able to slope the rear edge to help match that in the boat.
Once covered, the legs were reattached. When placed in the boat, I saw what you see in the pics ... a nice sun deck / bench for a 1993 MC PS190.
The "shoes" mentioned were created as sacrificial pieces to avoid the plywood leg edges from being on wet carpet possibly causing delamination. The shoes have yet to require replacement and likely never will. The shoes also provided a larger footprint for the leg, however, that was really not necessary. |
This is my $200 custom bench. |
Another view |
Lots of storage space underneath. |
View of starboard leg and "shoe". |
Side View |
View from astern. |
Close up of leg with shoe. |
Placement of shoe. |
Bench flipped out. |
Close up of shoe. Made from a piece of poplar with some quarter round and then several coats of danish oil. |
Bench on floor. Notice lawn mower ... the bench is big. |
1/8 inch nylon cord bowlined to eyebolt ties to handrail as insurance while trailering without the cover. NOTE: Departure has never occurred! |
View of bottom. |
Another view of bottom. |
Close up of port leg without shoe. |
Close up of middle support mounting slot. Also, a breathing hole with internal cloth covering protecting the 3 inch foam. |
Port side of aft seat edge. The dimples are caused by the screw heads mounting the shower pump. |
Starboard side of aft seat edge. |
Two small puncture marks on side wall upholstery immediately behind driver's seat. |