Amanda Knapp
Redecking a fibreglass boat is a common procedure for boat enthusiasts to restore their boats and keep them in good shape. Fibreglass boats are known for their low maintenance and durability, but they can suffer from age-related problems of fatigue and moisture, as well as damage from collisions and nature. This guide will explain the steps to redeck a fibreglass boat, including preparing the surfaces, replacing the stringers, and installing the deck flooring.
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What You'll Learn
Measurements and cutting
Before you start redecking your fibreglass boat, it is important to take accurate measurements and plan your cuts carefully. Start by measuring the size of the deck to determine how many sheets of material you will need. It is recommended to use separate sheets for the deck flooring, as this will make the installation process easier.
When taking measurements, use a tape measure to measure each side separately, as the sides may vary slightly in length. Mark out the measurements on your plywood sheet and cut the stringers accordingly using an electric saw. You will then need to fit these stringers into the boat and screw them together to create a solid frame.
The next step is to cut square holes in the deck sheets for all the fittings. Ensure you cut these holes in the appropriate areas, as you will pass the cables and connections through these holes as you lay each sheet. It is important to plan this stage carefully to avoid any mistakes that may affect the functionality of your boat.
Once you are happy with your measurements and cuts, you can begin placing the deck sheets. As you lay each sheet, pass the cables and connections through the square holes and continue until all sheets are in place. Finally, attach the sheets together with screws to create a unified deck.
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Applying fibreglass matting
When applying fibreglass matting to redeck a fibreglass boat, there are several steps to follow. Firstly, ensure you are working in a shaded, dry area, with temperatures between 21°C and 29°C. Prepare the boat by removing any extra items from the bottom, such as the keel, lift stakes, or rails. If you are replacing the stringers, take measurements for each side, as they may vary slightly. Use an electric saw to cut the stringers from the plywood sheet, then fit and screw them together to create a solid frame.
Next, measure the size of the deck and determine how many sheets of material you will need. Cut the deck flooring into separate sheets to ease the installation process. Cut square holes in the sheets for all the fittings on the deck. When you are satisfied with your cuts, begin placing the deck sheets, passing the cables and connections through the square holes before placing the next sheet. Once the deck is in place, attach the sheets together with screws.
Now, you can apply the fibreglass matting. Combine resin and hardener according to the product instructions, then pour the mixture into a paint tray. Apply the first coat of resin, known as the seal coat, to the deck. Once this is dry, apply the fibreglass cloth, followed by a second coat of resin, known as the bond coat. After this, apply a third coat of resin, the fill coat, and finish with a final coat of resin, the finish coat. This final coat should be thick enough to allow for even sanding.
Finally, sand the hull, starting with lower-grit paper and finishing with higher-grit paper. Give the hull enough time to dry, preferably overnight.
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Sealing and waterproofing
Prepare the Surface:
Start by preparing the marine plywood or substrate. Remove any loose parts, debris, or old sealant from the deck surface. Ensure the surface is clean, dry, and free of any previously applied products or residue. If there are any joints, seams, cracks, holes, or rough areas, use coarse sandpaper or sandblasting to smooth them out.
Prime and Patch:
Prime the prepared surface by applying a coat of a suitable primer like PermaFlex or a marine sealant. After priming, mix a liquid rubber base with a thickening activator and use this mixture to patch and profile any joints, seams, cracks, and holes. This step helps create a smooth and level surface.
Apply Sealant:
Once the patches are dry, apply a liberal amount of marine sealant to the deck. Work in a well-ventilated area and have all the necessary sealants, tools, and cleaning materials readily available. You can use a sealant like PermaFlex or choose a chemical sealant such as silicones, polysulfides, or polyurethanes, depending on the specific needs and compatibility with the deck material. Remember to follow the manufacturer's instructions for the best results.
Topcoat:
Finally, apply a topcoat to the deck for added protection and a finished look. You can use another coat of PermaFlex or your chosen marine sealant for this step. Remember to reapply the sealant regularly, ideally at least every three years, to maintain the waterproofing and protect your fibreglass boat deck.
By following these steps and maintaining a regular sealing schedule, you can effectively seal and waterproof your fibreglass boat deck, ensuring its longevity and protecting it from the elements.
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Screwing the deck in place
When screwing the deck in place, you will need to have already cut the deck flooring into separate sheets, as this makes installation much easier. You should also have passed the cables and other connections through the square holes in each sheet. Now, attach the sheets together with screws so that the deck is one solid piece.
Next, apply fibreglass matting all over the deck to make it water-resistant. This is an important step to protect the plywood from moisture damage. You can also apply a coat or two of epoxy resin to the underside of the plywood before bonding it into place. This will help to seal the plywood from any dampness.
Once the fibreglass matting and/or epoxy resin has been applied, fasten the deck with screws at the boat's edges. Apply a sealant to ensure that no water will penetrate the deck. Finally, reconnect the wiring by placing the centre console in place, connecting it with the cables, and screwing it in place. Position the seat and fasten its screws.
Now, start the engine to check whether the centre console is properly connected. With these steps complete, your new deck should be properly installed and ready for use.
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Reconnections and testing
Once the new deck is in place, it's time to start the reconnection and testing process. This involves several important steps to ensure the boat is safe and functional.
Firstly, attach the sheets of the new deck together with screws, creating a solid and unified structure. As mentioned earlier, applying fiberglass matting over the deck, including the stringers, is crucial for waterproofing. Make sure to cover the entire surface area of the deck with the matting.
Next, fasten the deck securely to the boat's edges using screws. Apply a sealant along the edges to ensure a watertight seal, protecting the boat from leaks. At this point, you can proceed to reconnect the wiring. Place the center console in its designated position and carefully connect the cables. Secure the center console with screws and then position and fasten the seat with screws as well.
Now, it's time to test the boat's functionality. Start the engine and carefully observe whether the center console is properly connected and functioning as it should. If everything operates smoothly, your redecking project is a success, and your boat is ready to hit the water again!
It is important to note that this job can be challenging, especially if you don't have experience with wood cutting and boat maintenance. If you encounter difficulties or are unsure about any steps, it is always best to consult a professional or seek advice from experienced boat enthusiasts.
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Frequently asked questions
The most common material used for boat flooring is BC plywood.
Use an electric saw to cut and remove the old damaged material.
All surfaces should be clean, dry and sanded.
Vinylester resin is better than most epoxies as it is thinner and more waterproof.
Attach the sheets of the new deck together with screws. Apply fibreglass matting all over the deck to make it water-resistant. Finally, fasten the deck with screws at the boat edges and apply a sealant.
