Originally Posted by zman2307
Consider a hybrid deck comprised of a fabricated shell with a stamped baffle system underneath - no buildup, with the strength of a fabbed deck. Like a reinforced 7ga outer shell and a 10ga underneath would be plenty. And you could use different baffle shells if you were going to make a northern-friendly deck and southern-grass friendly deck.
You could even make the baffle shell bolt-on, so mowers could be manufactured in mass quantities with the outer shell, and dealers could purchase them with the shell they need, plus it would be a piece of cake to make mulch kits fit up to it too.
Really, I don't know why anyone hasn't done this yet.