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n8kraft 04-25-2013 11:43 PM

Teak Deck Replacement with Nonskid
Today I started the BIG job of replacing my teak decks on my 1981 Cheoy Lee ketch. I just did a small section of the cockpit near my port jibsheet winch. I'm using this post as a guide. It took four hours from getting my tools out until the area is mostly clean.

The first step was removing the winch and two cleats from on top of the deck.
Here's the deck before removing the deck hardware.
They're off now. Then it was on to the wrecking bar and mallet to pry up the old teak. The screw heads stayed behind, so I used a flat tip screwdriver and vice grip pliers remove all the screws.

Next I scraped off the black bedding compound that held the teak in place. Most of it came up easily using a Fein Multimaster scraper tool.
Next I used acetone and a rag to remove the residual bedding compound. I wore nitrile gloves, but the acetone ate through them so tomorrow I'll be getting better chemical protective gloves. I switched to using a scotchbrite green scrubber with acetone and that helped the gunk come up quicker.

At the end I wiped down the surface and drilled out the hardware mounting holes, then reamed them out using a dremel tool. I'll rebed all the hardware later using this guide.
Now the deck is clear and is ready for the individual screw holes to be reamed and the holes to be filled with epoxy.

We have guests coming August 10 so my goal is to have the decks done by then. I guess I need to get to work!

jimgo 04-26-2013 11:01 AM

Re: Teak Deck Replacement with Nonskid
Wow, that's going to be a job! And I really hate to see the teak decks go; I love that look. But I can understand why you're getting rid of them.

So, what are you doing with all the teak? :)

Faster 04-26-2013 11:20 AM

Re: Teak Deck Replacement with Nonskid
I doubt very much of the decking came up in reusable pieces.

It's a daunting job, looks like you got off to a good start. SNer jrd22 did the same on his new-to-him boat, seems a good way to put that particular worry to rest.

n8kraft 04-26-2013 11:30 AM

Re: Teak Deck Replacement with Nonskid
I got a few long pieces up, but the underside had all the black sticky sealant so it's going in the marina dumpster.

mad_machine 04-26-2013 01:22 PM

Re: Teak Deck Replacement with Nonskid
the teak does not look that bad... just tired of cleaning and oiling it?

jimgo 04-26-2013 02:17 PM

Re: Teak Deck Replacement with Nonskid
N8, I'd bet some resourceful people would love that wood. Teak is expensive, and a trip through a properly set-up bandsaw would take off the sealant and probably still leave most of the wood. If you weren't on the other side of the country from me, I'd be tempted t make a deal. I have several projects that could benefit from long pieces.

n8kraft 04-26-2013 02:35 PM

Re: Teak Deck Replacement with Nonskid
The decks have worn thin with screwheads showing through and getting caught on shoes and toes. The nonskid properties get negated when the decks become a trip hazard.

arf145 04-26-2013 03:36 PM

Re: Teak Deck Replacement with Nonskid
And I suspect the OP was concerned about potential leaks through all those screw holes.

jrd22 04-26-2013 10:51 PM

Re: Teak Deck Replacement with Nonskid
Goodonya for starting this daunting task! Never having to worry about a rotten core, and the tremendous job/expense that entails, makes the work removing the teak and glassing over seem minor (when you're done with it :-)).

n8kraft 04-27-2013 01:39 PM

Re: Teak Deck Replacement with Nonskid
Yesterday my wife and I removed more deck hardware and teak. Now we have both sides of the cockpit cleared. Today we're having friends come over and they'll help remove the teak from the seats in the cockpit. Here's my first big challenge. With the teak removed there will be a lip and I'll need to decide if I'll remove that edge and fair it, or fill the space previously occupied by the teak.

Here are a few pictures from yesterday's hard work.
THe holes are all drilled out, vacuumed and filled. Some of the screw holes just kept sucking the epoxy. It's not dripping inside the cabin so there must have been a gap in the hull between the gel coat and the fiberglass, especially on the starboard side outboard.
The starboard side prepped. To remove the old sealant I used a paint scraper attachment with my drill to expedite the process.
Durabak nonskid coating samples. Top to bottom the colors are Tan, Creme and Sand. We're planning on using Sand because it compliments the wood trim the best. The nonskid is UV protected polyurethane so I can use the same primer that I'll use for the edges

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