Big day today, I was on company shut down but the wife had to work so I had plenty of time out in the garage. Started working on the bench conversion.
First I cut my new sheet of plywood to make the fuel tank cap. The left over would be the sun deck.
Then I deconstructed the old tiny sun deck to get the pattern for the back end, then traced that onto the leftover 3/4 ACX. Measured the width at the front of the piece and cut it out. Next I got some cardboard and traced the hull shape and transferred it to a sheet of 1/2 ACX for the back of the seat. This took a bit of time, little cut here little cut there. Probably would have been easier but I also cut it on a 5° angle so your not sitting so up right. Put a stripe of 1x2 on both top and bottom for support. Then cut the seat boxes out of the left over 1/2". the fronts are square but the back is angled to match.
Then I had to get my side panels and cut them down to match. Came out very nice.
The seat box construction is such that the top 1x2 pieces is glued and screwed to the seat back, so that they can always be put back in the same place. I made them so the seat boxes can come off to make it easier to remove/ assemble. Not sure if the seat back will be able to be removed with the side panels in and the motor. It will be close.
Lastly shaped the top hang over lip to the side panels. I wanted the gas tank to be accessible without removing the entire seat and also wanted somewhere for a cooler and other stuff to be stuffed which makes the middle blank under seat nice. The two other storage compartments ended up nice size as well. So the middle seat will be permanent and outside two removable.
I am very happy with the result. Probably going to have to remake the middle seat as it was a little small. Next is mounting points and then a little of finish like relief for water to run.