Replacing My Teak Deck After 47 Years

Aye Capt JB, I don't have the mold yet and might not for a few months. If that isn't a problem I'll make some nonskid for you then.

I got a second coat of POR 15 on the top of the tank. Tomorrow I'll change to white, It's completely covered now.

While I'm here, I need to figure out a better sound proofing. That old ceiling tile is crapola.

Capthead said:

While I'm here, I need to figure out a better sound proofing. That old ceiling tile is crapola.

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Try hdv - high density vinyl. It's amazing. There are lots of products but something like this should work extremely well..
http://www.supersoundproofingsales....W-w_Open-Cell-25-Roll/productinfo/09-00004-1/

This might be better for an engine room. Don't mind the price. It really is an amazing sound barrier. You won't regret it. It is heavy though.

http://www.supersoundproofingsales....ss-Loaded-Vinyl/productinfo/09-00003-CLASS+A/

Thanks for the tip. I'll see if my local marine hardware store has or can get it for me.

I cut out new plywood for the sub deck and placed them on the boat checking for the fit. It was good and I soaked them with CPES. I'll paint them with epoxy primer and top coat before I install them.

It's moving faster now that I have finished the fuel tank area, While I was here the cabinet in the forward head which is under the deck got a complete refurbishing too. So much easier to do from above too.

The outer edge of the longer board isn't cut yet. I'll do that today. I also have a deck fill hole to cut for the fuel tank and one of the engine room vent openings.

This is good stuff for ER

Sound Insulation - Vinyl Foam Barrier Composite - Soundtec | Fisheries Supply

Great work and enviable persistence and progress!

I had my foredeck replaced about 2 years ago, although I removed all the deck hardware and the teak itself. Previously the PO had someone lift the teak and then re-bed with some black stuff that doesn't harden unless exposed to air. But either it didn't keep out the water or the balsa core was already wet and continued to rot. The only good thing about that was they used square drive screws, and although they had to be cleaned out they came out fairly easy. All 960 of them. I salvaged most of the decking and am recycling into various items.

We cut the top GRP layer off in sections, stripped the balsa core out then ground the lower GRP skin smooth. There were no holes in it so no leaks into cabin. Then laid 1.5 oz CSM in vinylester resin, followed by bedding two layers of 6mm marine ply, ovelapping joints. We glassed over the top with 1.5 oz CSM, 2 x 24 oz woven roving and 2 layers of 1.5 oz matte. This provided a deck of the same thickness as the balsa cored one, enabling us to leave some of the upper GRP layer next to the bulwarks to slot the new deck ply and layup into. Faired with vinylester products and then awlgrip with micro-balloon non-slip.

Some pics: after teak removed,rotten balsa core, work in progress and finish. At some point I'll need to tackle some of the side deck areas, not just yet.

I love it!! Thanks for sharing Brian. When I see pride in ownership coupled with great workmanship and top quality products and labor, you can't go wrong.

This is exactly what I'm talking about.

I'll soon be there. It's just taking me a lot longer than I planned for. The good news is the weather is holding up and the detail I'm doing was much needed.

Brian, you are the MAN!!

How's it comin along mate?

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A lot has happened since my last posting. I was about to cut a piece of plywood for the top deck piece when a LA Port Police walked by and stopped me. I have had probably 50 cops walk by and never say a word because I use best practices while working. I always vacuum up after cutting and for the most part no sawdust gets in the water.

I'm not picking on short people but this was a very short man with a huge chip on his shoulder. He couldn't find any dust in the water and in fact, there was a gas spill of maybe 50 gallons but the possibility of my sawdust was of most concern to this banty rooster.

He threatened me with a 28,000 fine and said I can't do any work on my boat to haul it out. He said I can't cut on my boat either because sawdust could possibly blow off my boat and in the water. I was almost busting out laughing.

I cleaned up my work area and when he left I cut the boards.

He even emailed the dock master about me. What an ass.

I have proceed down the starboard side and have half of the engine room covered with the subdeck. I have the top deck cut and ready to install within a foot of that as I'm over lapping the joints.

You can see the old subdeck piece in the picture above. This is the top deck piece ready to be predrilled and set in place. I have to wait till Thursday to do this as we are having a heat wave today and tomorrow and the epoxy sets up too fast on days over 88. I have to cover 32 sq ft of deck with thickened epoxy placing this piece down.

LA Port Police? What a waste of skin. When you have made your last cut, make a formal complaint about harassment. I have a friend who was fined for scraping barnacles off a rock on his waterfront property. These are the same Fisheries yahoos who have overseen the decimation of herring, salmon, ground fish, you name it stocks on the West Coast, not to even mention the cod fishery on the east coast. Too many morons paid by taxes. Besides, we all know barnacles are endangered, although if you ever need to find one you could reliably look under my boat.

Think how much good this is doing to your legs, Stretch.

Go get umm Capthead. We always clean up while we are working also .I just bought a vacum / sander combo and spent a butt load of money for it because I was worried about the same thing. The wife keeps dip net handy for larger stuff. The tools we just donate to the river .
I'm kinda short and I get the short jokes a lot but it's ok . I guy just told me the other day he saw a guy shorter than me but it cost him quarter.

I'm getting my walk in for sure. My boat is 1/4 mile from the marina patio where the shop is. I'm carrying the wood up and back for each cut. Two cuts is a mile walk. It is a good thing. lol

I don't know what it is, but being 6'4" is a magnet to the complex driven. I attract them. Normal people leave me alone and I always have fun with everyone.

I have the sanders with the vacuum attachment too and talking to the tradesmen here, you just have to watch out for the port police. Funny thing is, none of the others say a word.

I painted the upper most inside hull and stringers with epoxy primer today. I have a day off tomorrow but Thursday I should be able to put the top deck part in place, secure the bulwarks and put a top coat of paint on where I primed today.

I got another section of top deck installed today. There was a lot of detail work to do and now I'm past the engine room. I already have the top deck pieces cut out and ready to install tomorrow.

The rectangle holes are engine room vents and they will be built up and covered with a clam shell so no water can enter the engine room.

Yes, those aer temporary stanchions and a high polished 1 1/4" stainless is goig back. I'm losing the bronze.

I'm finally down to my last 8' of teak deck to remove. The end is near for this phase.

Capthead said:

Yes, those are temporary stanchions and a high polished 1 1/4" stainless is going back. I'm losing the bronze.

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I kinda like the Trawler Trash look of cheap lumberyard wood scraps!

Seriously, nice work, Stretch! What a huge job.

FlyWright said:

I kinda like the Trawler Trash look of cheap lumberyard wood scraps!

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I am on facebook and several people said they wanted to see pictures of my work. I posted this picture yesterday just before posting it here and someone who owned a Grand Banks asked if those were my permanent stanchions.

I had to laugh

That's why I mentioned it here.

They are functional and they are keeping the termites away from the teak rails.

The top deck pieces are now epoxied in place screwed and permanent. All that is left is the last 8 feet of side deck.

Today I am going to secure the bulwarks I cut from the deck back to the new deck down to within a few feet of the end of the new section. This way I can cut the last 8 feet of bulwarks off the old deck and start removing that section. I like to keep the bulwarks supported and in place.

I have finally removed the last 8' of teak deck from the boat. This last section was the hardest and the subdeck plywood was divided between the best and worse on the boat. What I found was when they installed the bulwarks on the boat they hadn't filled the deck seams yet and at the outside edge there was a 1/2 width piece od teak decking. The bulwarks fit right over the seam and covered it about 1/8th inch. It made a wide open trench for water to get below the teak and rot the subdeck plywood.

Also, food for mold and such so right beside our bed behind the nice teak wall was black mold growing on the inside of the hull. the rest of the subdeck was a bear to remove because it was good and the nails were holding well.

It's cleaned, 2 gallons of bleach later, sealed with CPES and ready for new paint.

I'm so glad the deck has been removed and I only have 8' of sub and 10' of top decking to do.

As you can see, britework is next. This is the last remains of the 10 yr varnish I used. My wife sAYS IT WAS 1998 when I put it on. I think she's right too. That means it lasted long after 10 years and I have places where it looks great still.

I guess this is what's called "getting to the home, Stretch(!)"

Keep at it and keep the photos coming.

Looking great, Stretch! What a herculean task you've accomplished.

Keep at it man nice work. This thread has been an excellant motivator for those who think they can't ever get it done.

Capthead said:

I got another section of top deck installed today. There was a lot of detail work to do and now I'm past the engine room. I already have the top deck pieces cut out and ready to install tomorrow.

The rectangle holes are engine room vents and they will be built up and covered with a clam shell so no water can enter the engine room.

Yes, those aer temporary stanchions and a high polished 1 1/4" stainless is goig back. I'm losing the bronze.

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Oh yeah what you gonna do with the old bronze stanchions?