Redecking Aluminum Boats: A Step-By-Step Guide

Redecking a boat is a big job, but it can be a rewarding DIY project that saves you money. If you're thinking of redecking your aluminum boat, there are a few things to consider. You'll need to decide on the type of decking material you want to use, such as aluminum, composite boards, marine-grade plywood, or vinyl planks. Each option has its pros and cons in terms of cost, weight, durability, and maintenance. You'll also need to remove the old flooring and prepare the surface before installing the new deck. This may involve sealing or treating the plywood to protect it from water damage. Additionally, you'll need to choose the right tools and consider factors like wiring and carpet installation. Overall, redecking your aluminum boat can be a challenging but satisfying project that gives your boat a new lease of life.

Removing the old flooring

Start by moving your boat onto dry land, if it isn't already, and removing all the seats, the top, and the rails. It's important to keep your boat covered when not in use to prevent water damage and mould, which can be time-consuming and costly to fix.

Next, disconnect the console and carefully label the electric wires. Take pictures as you go, so you know which wires connect where when it's time to reassemble. You should also disconnect the battery to avoid any accidents.

Now it's time to remove the old flooring. If you have carpeting, start by removing this first. Take your time with this step, as you may uncover problems like mould or saturation that will need to be addressed before installing your new flooring. Allow plenty of time for your boat to dry out and air out before proceeding.

Once the old flooring is removed, you'll need to clean and prepare the surface for the new decking. This may involve sealing the plywood with epoxy or fibreglass resin, especially if you plan to use marine-grade plywood, which requires a sealer to become water-resistant.

Finally, if you're replacing the carpet, you'll need to remove the old glue or adhesive. This step can be labour-intensive, so be prepared for a thorough job.

Choosing the right material

When it comes to choosing the right material for redecking an aluminum boat, there are several options available, each with its own advantages and considerations. Here are the key factors to consider when selecting the most suitable material:

Aluminum

Aluminum is a lightweight and easy to install option for redecking. It requires minimal maintenance and is highly resistant to rust and stains. However, one of the main considerations is cost. Aluminum can be expensive, especially if a custom order is required. It is important to weigh the benefits of its durability and low maintenance against the upfront cost.

Composite Boards

Composite boards, made from blends of plastic, wood, and other materials, offer a lightweight and low-maintenance solution. They are easy to work with and won't warp over time. However, composite boards may require additional underlying support, and there is a chance of mold or peeling. Similar to aluminum, composite boards can be on the pricier side.

Marine-Grade Plywood

Marine-grade plywood is constructed with high-quality plywood and waterproof glue, making it capable of withstanding high humidity levels without deteriorating. It strikes a balance between strength and lightweight properties. However, to make it water-resistant, a sealer needs to be applied, which adds to the overall expense of the project.

Pressure-Treated Plywood

Pressure-treated plywood is an affordable alternative to marine-grade plywood. It has been treated to prevent water damage and is resistant to rot, algae, insects, and other common issues. This option has been popular for years due to its durability and cost-effectiveness. However, it's important to note that the chemicals used in the treatment require protective equipment during installation and have specific disposal regulations that must be followed.

Vinyl Planks

Vinyl planks offer the aesthetic appeal of wood without the maintenance hassles. They are waterproof, durable, and skid-resistant. While vinyl planks provide a convenient and attractive option, they come at a higher cost.

When choosing the right material for redecking an aluminum boat, it's essential to consider factors such as durability, maintenance requirements, cost, and ease of installation. Each material has unique characteristics, so selecting the most suitable option depends on specific needs, preferences, and budget constraints.

Preparing the new deck

Once you've selected the material, you'll need to cut it to size, ensuring it fits the dimensions of your boat. If you're using plywood, consider sealing it with epoxy or fibreglass resin to protect it from water damage. This step may not be necessary for aluminium, but you may want to add an extra layer of protection to prevent corrosion.

The next step is to prepare the boat for the new deck installation. Ensure the boat is on dry land and remove all necessary components, such as seating, rails, and the console. Label the wires to make reassembly easier. If you're replacing the flooring near the console, you might need to remove it or cover it with a protective layer to avoid damage.

Now, you're ready to install the new deck. This process will vary depending on the material you've chosen. For aluminium, you may use screws or rivets to secure the plates to the boat ribs. For plywood, screws or glue can be used. Ensure that you follow the manufacturer's instructions for the specific type of glue or adhesive you're using.

Finally, once the new deck is installed, you can proceed to reinstall the removed components, such as the seating and rails. Make sure to connect the wires correctly, referring to the labels you made earlier.

Installing the new deck

When installing the new deck for your aluminium boat, there are several options to consider. Firstly, decide on the material you will use. You could use plywood, composite boards, aluminium, or vinyl planks. Each option has its advantages and disadvantages in terms of cost, weight, durability, and maintenance requirements. For example, aluminium is lightweight, easy to install, and low-maintenance but can be costly. On the other hand, plywood is more affordable but may require additional sealing or treatment to prevent water damage.

Once you have selected the material, cut it to size, ensuring it fits the dimensions of your boat. If you are using plywood, consider sealing it with epoxy or fibreglass resin to protect it from water damage. You can also apply a sealer to make it water-resistant. Additionally, consider adding an extra layer of support underneath, especially if you are using composite boards, as they may require additional support.

Next, attach the new deck to the boat's frame using screws or rivets. Stainless steel screws are a good option, or you can use aluminium rivets if the boat will be used in saltwater. Make sure to screw or rivet the new deck securely to the ribs of the boat for a solid installation. You can also use foam underneath for added support and to reduce any rattles. Silicone can be used between the ribs and the deck for a smoother finish.

Finally, consider adding a carpet to your new deck for added comfort and aesthetics. Choose a marine-grade carpet with UV protection, and use marine-grade carpet glue to ensure it adheres properly. Apply the glue liberally and quickly, and use a carpet roller to create an even finish.

Reinstalling extra parts

Once you have finished redecking your aluminum boat, it is time to reinstall the extra parts. This includes the seating, rails, and console.

First, reconnect the console and label the electric wires. If you took pictures of the wiring before you began, refer to these now. It is important to get the wiring correct, so take your time with this step.

Next, reinstall the seating and rails. Ensure that these are secure before moving on.

If your boat has a steering cable, now is the time to reconnect it. Again, take your time and ensure that this is done correctly.

Finally, check over your work and ensure that all parts are secure and correctly installed. Once you are satisfied, your boat is ready to hit the water!

Remember, safety should always be a top priority when working on any boat-related project. If you are unsure about any aspect of the redecking or reinstallation process, seek advice from a professional or experienced boat builder.

Frequently asked questions