Advice on replacing a wooden deck on a fiberglass boat (Able 20')

[brendan.m.slagle]

Hi Guys,

I was wondering if anyone could give me some advice on replacing the wooden deck on an otherwise fiberglass sailboat. The boat is an Able 20', which you have probably never heard of because there were apparently not too many that were made. Its a 20' sailboat with a fiberglass hull, shoal keel, and a teak & holly deck portion of the bow set in the fiberglass topside. The marine ply was completely rotted out so I removed it. Now I am trying to figure out the best way to replace it on a budget without sacrificing the unique look of the wood finish.

Here's what I have considered so far:

1) Teak & Holly marine ply epoxied in and finished - Not cheap

2) Teak decking, actual teak boards - Also not cheap, labor intensive, structural weakness?

3) Mahogany or similar marine ply - more affordable, awkward look?

4) Cheap marine ply or foam core covered in glass - affordable, boring look

I don't really know of too many other options. I am super broke, but I really want to sail this boat before it snows this year. Any advice would be greatly appreciated.

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[Darren Nemeth]

Re: Advice on replacing a wooden deck on a fiberglass boat (Able 20')

IMHO, Douglas Fir ply looks really nice when I paint resin on it. The grain structure is different though so it will be a different look.

Maybe there would be a way to stain the wood or darken the resin to give it a "finished" look?

 

[bigredinohio]

Re: Advice on replacing a wooden deck on a fiberglass boat (Able 20')

Hi Guys,

Here's what I have considered so far:

1) Teak & Holly marine ply epoxied in and finished - Not cheap

2) Teak decking, actual teak boards - Also not cheap, labor intensive, structural weakness?

3) Mahogany or similar marine ply - more affordable, awkward look?

4) Cheap marine ply or foam core covered in glass - affordable, boring look

I don't really know of too many other options. I am super broke, but I really want to sail this boat before it snows this year. Any advice would be greatly appreciated.

If you are "super broke," then which of your options are realisticly affordable? Only you can answer that yourself. You may have to sacrafice a "wish" option for "reality" item if you want to sail before snow! In a few years, you could redo for an upgraded look when funds allow.

 

[allpoints360]

Re: Advice on replacing a wooden deck on a fiberglass boat (Able 20')

Get it cleaned up, replace the marine ply (not cheap), seal it and go sailing. You can add the teak over the winter.

Are you sure you had holly topsides?

 

[lowkee]

Re: Advice on replacing a wooden deck on a fiberglass boat (Able 20')

How about some white birch plywood with cedar stain and a light coat of glass (so it remains transparent, yet waterproofed)?

You can also veneer it and then add glass to keep costs down. I know most people think "Oh my trashy!" when veneer comes up, but it isn't just for cheezy butcher block countertops, veneer is how most sleight beds are made as well as many, many curved surface furniture (even the pricey stuff). You can buy pretty much any wood type as a veneer, likely teak too, on the internet. Nobody is going to care if it is solid teak or birch or anything.. as long as it doesn't crush under human weight and looks pretty, you have a perfect boat.

 

[brendan.m.slagle]

Re: Advice on replacing a wooden deck on a fiberglass boat (Able 20')

Thanks for the advice guys.

allpoints360 - The deck was teak/holly marine ply, not individual planks

lowkee - Are veneers suitable for marine use?

Another question I have is with regard to the perimeter of where the marine ply will go. If you look at the picture you can see that the inner and outer portions of the glass where the ply will go are hollow. They were filled with wet rotted foam (which I am still working on removing the last of). I know the "Great Stuff" expandable foam you get at home depot shouldn't be used for structural/flotation purposes, but what about filling that 1/2" by 1.5" space? Can that stuff be sealed with resin or will it get eaten up by it?

 

[ghamby]

Re: Advice on replacing a wooden deck on a fiberglass boat (Able 20')

From the picture, this one doesn't look like a prize contender at the used boat
show. I would remove all the old foam core you can around the cabin, hatches,
and such.Sand down the sub deck with about 80 grit, just to even things out.
Get some Airex foam core material or equivalent and epoxy it down. Glass the
foam with mat and epoxy. Sand and paint that and either paint on nonskid
areas or epoxy down nonskid rubber decking.

 

[lowkee]

Re: Advice on replacing a wooden deck on a fiberglass boat (Able 20')

Thanks for the advice guys.

allpoints360 - The deck was teak/holly marine ply, not individual planks

lowkee - Are veneers suitable for marine use?

Tissue paper is suitable for marine use if properly fiberglassed over. Think of plywood as multiple layers of veneer glued together, since that is exactly what it is.

 

[wizbang 13]

Re: Advice on replacing a wooden deck on a fiberglass boat (Able 20')

Is the existing glass deck strong ? I'd grind off thoses cabin ,cap, hatch flanges(16 grit@5000rpm)and put epoxe filets ,36 grit /grind the decks and paint with west, then interlux 404/414,then non skid top coat. No 20 'er needs extra weight.Good paint is better than bad varnish.

 

[brendan.m.slagle]

Re: Advice on replacing a wooden deck on a fiberglass boat (Able 20')

Unfortunately the glass underneath is not strong at all. I am leaning more and more towards ditching the wooden topside idea and just filling with foam core and coating with glass. We will see what happens though. With the early cold snap up here in NH this might have to wait until spring...

 

[wizbang 13]

Re: Advice on replacing a wooden deck on a fiberglass boat (Able 20')

In that case I would lean towards the AIREX cure,(ghamby). Added advantage of foam sandwich is less condensation,cooler in summer and warmer in winter.