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.
Step 1: Sketch design on cardboard
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.
Step 2: Glue wood together
Once the piece was dry I ran it thru the planer until it was clean and flat, then ran my shopbot file on it.
Step 3: Router grooves in sides for pizazz
Step 4: Seal plank, then drill holes for attachment hooks
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.
Step 5: Install hooks and secure deck to bike
Now, go for a ride.