Flight Deck Materials

Flight Decks can be built from a few different materials. Here are some pros, cons, and tips for choosing and working with the materials.

Plywood

Plywood comes in several thicknesses. Probably the most common will be 3/4" and 1/2".

Pros

Inexpensive

Easy to find. Most home centers will carry it.

Easy to work with

Cons

The grain of plywood is difficult to mask in order to make it look like metal. It will normally take several coats of primer and sanding to create a smooth surface.

Finding straight pieces can be difficult. Storing it normally forms bows or ripples that may be difficult to remove.

Swells when wet. Prime all sides.

Builder Tips

To minimize the amount of end grain showing and/or to save weight, some have tried building a frame of structural lumber and sheathing it with 1/4" plywood such as luan. Getting joints to look good is very difficult using this technique and the thin plywood has more ripples than the thicker versions.

Using 3/4" ply for a base is less expensive than other materials and the grain can be covered with vinyl or rubber tiles or commercial carpet tiles. It provides something to fasten the MIP and side consoles to, in order to create a more rigid structure.

Medium Density Fiberboard (MDF)

MDF also comes in several thicknesses.

Pros

Inexpensive. Generally the same price as BC plywood.

Smooth faces. Less sanding needed.

Stiffer and generally straighter than plywood.

Works just like plywood. Note that you really need a dust mask when cutting MDF and it will dull saw blades faster than plywood.

Cons

Heavier than plywood of the same thickness

Swells when wet. Prime all sides.

Builder Tips