Amanda Knapp
Owning a boat is a costly affair, and maintenance is an integral part of it. Despite best efforts, wear and tear is inevitable, and you may need to repair your boat eventually. One of the most common repairs is replacing the boat deck fiberglass. The first step is to assess the damage and determine its extent and whether it is structural or cosmetic. Once the damage is assessed, you can start the clean-up phase by removing the old, damaged material using a saber saw, crowbar, hammer, chisel, pick, and a drill with screw bits. After the clean-up, you can cut new marine plywood to fit and paint the underside with a thick coat of resin to protect against moisture. Finally, attach the sheets together with screws, apply fiberglass matting to make it water-resistant, and fasten the deck with screws at the boat edges.
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What You'll Learn
Removing the old deck
Removing the old boat deck is a tedious but necessary chore. The first step is to cut out the old, rotten deck or the section that is rotten. This can be done with an electric saw or a saber saw. It is important to set the saw blade correctly by first drilling a hole and using a probe to measure the thickness of the deck. This will help to ensure that you don't cut too deep and damage the bulkheads or hull. Once the rotten deck is cut free, use a hammer and chisel to chip away any remaining pieces of fiberglass putty or resin from the stringers and bulkheads.
The next step is to remove the old fasteners. This involves using a hammer and pick to chip away the fiberglass resin that is covering the screw heads. In some cases, you may be able to leave the screw heads in place, but you will need to be careful not to damage them when installing the new screws. It is also important to inspect the stringers and bulkheads for any damage and replace them with fiberglass ones if necessary.
Before installing the new deck, it is important to prepare the surface by sanding and cleaning the fiberglass a few inches beyond the repair area. This will ensure that the new deck has a smooth surface to adhere to. If you are replacing the deck up to the gunwales, you may want to run putty around the edges to create a radius, as fiberglass does not handle sharp angles well.
When removing the old deck, it is important to be cautious and take your time. Wear protective gear, such as gloves and eye protection, to shield yourself from any sharp pieces of fiberglass or wood. It is also helpful to have a friend assist you, especially when cutting and lifting the old deck.
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Choosing the right materials
For a durable and long-lasting solution, many boat owners choose fiberglass decks. Fiberglass, when combined with resin, creates a sturdy material that can withstand harsh environments and protect the deck from water damage. To achieve optimal results, it is essential to assemble the necessary tools and supplies beforehand. This includes items such as chopped strand mat or knitted fabric, paintbrushes, rollers, spreaders, and resin.
When working with fiberglass, it is crucial to ensure you have enough resin on hand. Sanding and redoing fiberglass work due to insufficient resin can be time-consuming and challenging. Additionally, it is important to be cautious when cutting and removing the old deck to avoid damaging other components of the boat, such as fuel lines, tanks, wires, or the hull.
In some cases, boat owners may consider using alternative materials for their decks. One such option is Coosa, which comes in different thicknesses, fiberglass strengths, and densities. Coosa offers two lines of panels: Bluewater and Nautical, with Bluewater being stiffer and Nautical being lighter in weight. Another alternative is foam decking, which has varying lifespans depending on the climate. Most manufacturers offer warranties and projected service lives for their foam deck pads, and professional installation can enhance the longevity of this material.
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Preparing the new deck
First, you need to cut the new marine plywood to fit the dimensions of the boat deck. This step can be challenging, especially if you need to match radiuses around the bow. It is recommended to use a circular saw for this task. Before cutting, it is important to take accurate measurements to ensure a proper fit.
Once the plywood is cut to size, you should paint the underside with a thick coat of resin. This step is crucial in protecting the wood from moisture and water damage. You can use epoxy resin or, in the case of teak and mahogany, epoxy is necessary due to the natural oils and tight grain of these woods. Apply a coat or two of epoxy resin to the underside of the plywood before bonding it into place.
Next, attach the sheets of plywood together with screws. This will ensure that the deck is one solid piece. After the plywood is secured, apply fibreglass matting or cloth over the entire deck. This step will make the deck water-resistant and provide strength. You can use a combination of fibreglass cloth and resin, or you may opt for fibreglass putty to fill in any gaps or sharp angles. It is important to note that fibreglass does not adhere well to sharp angles, so you may need to use putty to create a radius around the edges.
Finally, fasten the deck to the boat edges with screws and apply a sealant. This will ensure that no water can penetrate the deck. You can use a marine-grade sealant or caulking to create a watertight barrier.
By following these steps, you will have a well-prepared new deck that is ready to be installed on your boat. Remember to take your time, work in a safe and well-ventilated area, and always wear the appropriate protective gear when working with fibreglass and resins.
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![[Black] 3oz Marine Adhesive Sealant 5200 Fast Cure - Permanent, Watertight Bonding and Sealing - UV Resistant, Above & Below Waterline- for Boats, Hulls, Decks & RVs,Pond Sealant](https://m.media-amazon.com/images/I/717Qkl7fJDL._AC_UL320_.jpg)
Installing the new deck
Installing a new boat deck requires careful preparation and the right tools and materials. Here is a step-by-step guide to installing a new fiberglass boat deck:
Prepare the Surface
Before installing the new deck, ensure that the underlying structure is sound. If there are any soft spots or warping, address these issues first. Remove any damaged or rotten sections of the deck or stringers and bulkheads, taking care not to damage the hull. Use a saber saw to cut out the damaged sections, and a hammer and chisel to chip away any remaining pieces. Drill holes and use a probe to measure the thickness of the deck before cutting, to ensure you don't cut too deep.
Install Marine Plywood
Cut new marine plywood to fit the area. Treat the plywood with a thick coat of resin to protect it from moisture. You can also apply epoxy resin to the underside of the plywood to seal it before installation. This step is crucial to prevent water penetration and subsequent rot.
Apply Fiberglass
Apply fiberglass matting or cloth to the deck to make it water-resistant. Overlap old surfaces with glass where possible, and sand and clean the fiberglass surfaces beyond the repair area to ensure a smooth finish. When working with sharp angles, use putty to create a radius, as fiberglass doesn't handle sharp angles well.
Secure the Deck
Attach the sheets of plywood together with screws to secure them in place. Fasten the deck with screws at the boat edges, and apply a sealant to prevent water penetration.
Reconnect Wiring and Components
Reconnect the center console and wiring. Place the center console, connect the cables, and screw it into place. Position the seats and fasten their screws. Start the engine to test that the center console is properly connected.
With these steps, your new fiberglass boat deck will be installed and your boat will be ready for its next adventure.
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Final surface application
The final surface application is an important step in the process of replacing a boat deck with fibreglass. This stage will only take a few hours if you use a kit. Before beginning the final surface application, ensure that you have prepared the old surfaces and overlapped them with glass, where possible. When replacing a piece of rotten decking, prep (sand and clean) the fibreglass surfaces a couple of inches beyond the repair itself so you can overlay the glass around the edges.
When replacing a deck right up to the gunwales, you may want to run putty around the edges to create a radius, as fibreglass hates sharp angles and laying a neat 90-degree turn is very difficult. Once the deck is in place, attach the sheets together with screws so that it will all be one piece. As with the stringers, 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 to prevent water penetration.
If you are not using carpet, make sure the final layer of resin has a wax in it so it cures tack-free. Polyester and vinyl ester resin, without wax, will cure tacky. If you are working with epoxy resin, this is not an issue as it will cure without a tack. You can use one layer of 1708 with epoxy on the deck, which will last forever. If you want to save money and the wood is structurally sound, use vinyl ester resin with two layers of 1.5 oz chopped strand mat. Then top it with a coat of unwaxed gel coat and a layer of wax gel coat with silica mixed in for some grip.
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Frequently asked questions
To remove the old boat deck, you will need a saber saw, crowbar, hammer, chisel, pick, and a drill with screw bits. Start by drilling a hole in the deck and using a probe to measure its thickness. Then, use the saw to cut around the perimeter of the deck, being careful not to cut too deep. Once the deck is cut free, rip up the old wood and chip away any remaining pieces from the stringers and bulkheads.
The most common material used for boat flooring is BC plywood, which is then covered with fiberglass. You will also need fiberglass resin, fiberglass putty, a sander and sandpaper, screws, and a sealant. To attach the plywood to the stringers, you can use epoxy resin or vinylester resin.
First, cut the new marine plywood to fit the deck. Paint the underside with a thick coat of resin to protect against moisture. Then, screw the plywood into place and apply fiberglass matting all over the deck to make it water-resistant. Finally, seal the edges with putty and reconnect the wiring and console.
The amount of resin and cloth needed will depend on the size of the deck. For a 7x12 foot deck, you will need about 10 square yards of material. This typically translates to 2 layers of 1.5 oz chopped strand mat with vinyl ester resin.
