RP172 lower bunk mod?

it was tricky and it barely fit back in, did you buy the kit from camping world?

I decided to add some struts to help lift the lower bunk platform.  The install went ok, but the 3/8" plywood deck was in pretty tough shape, and the hinges were installed pretty poorly at the factory - all askew and really close to the edge of the plywood.  After a month of use the hinges just ripped out of the plywood.  (yes, the struts i used are probably overkill, but that horse has left the stable).

No problem!  I went and got some 5/8" material so i could replace the bed deck and the 10" strip of plywood at the leading edge of the bunk.  I also got a 72" piano hinge to make sure the sucker worked.

Got everything cut, and went to pull the old 3/8" pieces out...and the big piece doesn't fit.  I can't get the darn thing out .

Has anyone done this?  Do I really need to remove the top bunk in order to get the bottom bunk deck out in one piece?  Obviously i could cut it, but that won't help me getting the new, thicker, heavier piece back in.