Andrew Pace
Building a deck on a fiberglass Jon boat is a complex process that requires careful planning and execution. One of the key challenges is finding the right materials and methods to ensure a sturdy and durable structure. Some boat enthusiasts opt for aluminum framing, which can be welded, brazed, or bolted together, while others prefer to use wood, such as plywood or cedar, for the deck. It is important to consider the weight and bulk of the materials, as well as their compatibility with the fiberglass boat to avoid damage or leaks.
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What You'll Learn
Using aluminium angle and plywood
When framing a fibreglass Jon boat deck using aluminium angle and plywood, there are a few key considerations to keep in mind. Firstly, determine the appropriate thickness of the plywood and aluminium angle. The thickness of the plywood can be 1/4", 1/2", or 3/4", and the thickness chosen will impact the spacing of the aluminium angle framing. For example, if using 1/2" marine-grade plywood, the aluminium angle framing should be spaced 16" OC (on-centre). Thicker plywood will result in heavier weight, so this should be considered when choosing the thickness.
Another factor to consider is the anticipated weight load on the deck. For example, if a 200 lb person will be walking on the deck, the framing should be designed to support that weight. The span distance between connections and the distance between framing members will also impact the required thickness of the aluminium angle. If you have short spans of around 42", you can use smaller aluminium angle pieces, such as 1.5 x 1.5 x .125". For longer spans, you may need to use larger profiles and run them perpendicular to the long span to provide adequate support.
When choosing plywood, it is recommended to use marine-grade plywood that is untreated. Treated plywood can cause corrosion issues with the aluminium due to the presence of copper. Marine-grade plywood is made with more ply layers, glued with moisture-proof/resistant glue, and does not require additional coating. However, some people choose to coat it with polyurethane or a truck bed liner to provide extra protection.
The aluminium angle and plywood can be sourced from hardware stores such as Lowes, and the framing can be designed to bolt together or be welded, depending on your preference and skill level. It is important to plan the layout carefully, considering the spacing and weight distribution to ensure a sturdy and functional deck for your Jon boat.
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Extending the front deck
When extending the front deck of a fiberglass jon boat, there are a few things to consider. Firstly, it is important to use the right materials and techniques to ensure that the extension is sturdy and secure. One option is to use brackets to support the plywood on the fiberglass. However, as noted by some boat enthusiasts, there is a concern that drilling brackets into the fiberglass could cause it to crack.
To address this, it is recommended to use glassing techniques to add side rails for support instead of mechanical fasteners. This involves using fiberglass mat and cloth strips to attach a strip of wood to the hull, which will provide a sturdy base for the deck extension. Before attaching the wood, it is important to kerf it, or make cuts, so that it can bend and curve to fit the shape of the boat. These cuts should be made using a table saw, radial arm saw, or circular saw, with a depth of about 1" every 1/2" or spaced about 1/4" to 1/2" apart.
When attaching the wood to the hull, it is crucial to use the appropriate tape and resin to create a strong bond. Clear packing tape, similar to that used for sealing cardboard boxes, should be used to seal off the kerfs on the bottom of the wood to prevent resin leakage. Once the tape is in place, a resin/hardener mixture can be poured into the kerf cuts, creating a sturdy attachment between the wood and the hull.
Additionally, when considering the framing of the extended front deck, some have suggested using aluminum angles for the frame with composite plywood decking. This can be mounted to the support ribs inside the boat using pop rivets or short screws. To ensure sturdiness, it is recommended to place rivets every 3 inches. You can also add vertical supports in the middle of the deck for extra strength.
By following these steps and techniques, you can effectively extend the front deck of a fiberglass jon boat, creating a secure and sturdy platform that can also provide additional storage space.
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Using brackets to support plywood
When it comes to using brackets to support plywood in the framing of a fibreglass jon boat deck, there are several options and considerations to keep in mind. Here are some detailed instructions and suggestions:
Choosing the Right Brackets
Firstly, it is important to select suitable brackets for the job. You can opt for L-brackets, which can be screwed into the fibreglass to support the plywood. However, there are concerns about the fibreglass cracking during the drilling process, and the strength of the hold. As an alternative, some people recommend "glassing" in side rails for support instead of using mechanical fasteners.
Materials and Techniques
When it comes to the materials and techniques for supporting plywood, there are a few options. One suggestion is to use aluminium angle brackets, which are lighter than wood supports. These can be mounted to the support ribs inside the boat using pop rivets or short screws. It is recommended to space the pop rivets every 3 inches to ensure sturdiness. Additionally, you can bolt the angles together to form a square and then set it in place. To further enhance buoyancy, consider adding some styrofoam underneath the structure.
Another technique involves kerfing the wood to make it flexible enough to follow the curves of the boat. This can be done using a table saw, radial arm saw, or circular saw, with cuts spaced about 1/4" to 1/2" apart. After kerfing, use a grinder or sander to smooth the area where the railing will be attached.
Pre-made Brackets
There are also pre-made brackets available on the market that can simplify the process of joining plywood together. For example, Ply90 corner brackets allow you to attach two sheets of plywood at a 90-degree angle without drilling or screwing into the plywood. These brackets are made of high-strength aluminium alloy and are suitable for plywood with a thickness of 0.450" to 0.755". However, they may be more appealing to furniture designers or those seeking an industrial-chic style, and the cost may be a factor to consider, with a four-pack priced at $30.
Custom Brackets
If you are unable to find suitable pre-made brackets, you can explore custom options. Local metal fabrication companies can create custom brackets, but they may be more expensive, typically costing around $30 per piece. Another option is to find places online that offer custom pieces, or you could even consider 3D printing the brackets using metal or other tough materials.
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Using glue or epoxy to attach carpet
When it comes to using glue or epoxy to attach carpet to a fibreglass jon boat deck, there are several considerations and methods to keep in mind. Firstly, it is important to ensure that any epoxy or glue used is suitable for maritime use and will form a strong bond with the fibreglass surface. Some recommended products include Weldwood All Weather Outdoor Carpet Adhesive and Kwik Grip Vertical Contact Adhesive, which is designed for marine carpet and can adhere to most maritime surfaces.
Before gluing or epoxying the carpet, it is crucial to prepare the surface properly. This includes cleaning and drying the deck to ensure that the adhesive will bond effectively. If there are any irregularities or damage to the fibreglass, it may be necessary to sand or repair the surface for a smooth finish. Additionally, the carpet should be cut to size, ensuring it fits the deck area perfectly.
When applying the adhesive, it is essential to follow the manufacturer's instructions for the best results. Typically, the adhesive will need to be spread evenly across the deck and the carpet, taking care to avoid any gaps or air bubbles. The carpet should then be carefully laid onto the deck, smoothing out any creases or bumps. Depending on the adhesive used, you may need to apply pressure or weight to the carpet to ensure a strong bond.
It is important to allow the adhesive to cure completely before using the deck. This curing time can vary depending on the product used and environmental conditions, so it is crucial to refer to the manufacturer's guidelines. Once cured, the carpet should be securely attached to the fibreglass jon boat deck, providing a durable and attractive finish.
Some additional considerations include the use of staples or mechanical fasteners. While they can provide extra security, they may also create holes that can trap water and potentially damage the underlying structure. Therefore, it is generally recommended to rely solely on the adhesive for attaching the carpet, as staples or fasteners are not necessary and can create more risk for water damage.
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Using wood vs aluminium framing
When it comes to framing a fibreglass jon boat deck, there are two primary materials to consider: wood and aluminium. Both have their advantages and disadvantages, and the choice between the two depends on factors such as cost, ease of installation, durability, and weight.
Wood, such as Douglas fir, is a popular choice for boat decking due to its affordability, ease of installation, and familiarity for builders. It is also a good option if you want to avoid drilling into the fibreglass, as wood can be attached using brackets or glassing in side rails for support. However, wood is more susceptible to warping and rotting over time, especially if it is not properly treated and sealed. It is crucial to consider that every hole drilled into the wood may provide a way for water to enter, potentially leading to damage.
On the other hand, aluminium is known for its lightweight yet sturdy nature. It is strong, durable, and resistant to corrosion, ensuring that it will last the life of the boat. Aluminium framing is also easier to work with than wood and does not require the same level of treatment to prevent water damage. However, aluminium is generally more expensive than wood, and the price can be a significant consideration for some boat owners.
While wood may be more cost-effective and accessible, aluminium offers superior longevity and lower maintenance. It is essential to weigh these factors when deciding on the framing material for your fibreglass jon boat deck.
Ultimately, the decision between wood and aluminium framing depends on your specific needs, budget, and comfort level with the materials. Both options are viable, and many boat enthusiasts have successfully used either wood or aluminium to frame their jon boat decks.
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Frequently asked questions
Aluminium angle and plywood coated with gluvit are good options for framing a fibreglass Jon boat deck. Aluminium is lighter than wood supports and is also more cost-effective.
You can use L-brackets to screw into the fibreglass and support the plywood. However, some people recommend using glassing to add side rails for support instead of mechanical fasteners.
For a waterproof glue, you can use the carpet glue sold at West Marine. You can also use spar urethane, epoxy, or outdoor carpet adhesive.
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