Pontoon Deck Replacement....

[SolomonMan]

All,
I have a 1990 Sun Tracker Party Barge 24ft.

I am considering replacing the deck this year and I need to know approximately how long will it take for a crew of two people to remove the deck and reinstall new. I have a great deal of experience with Carpeting and Flooring (Family business).

I have tools at my disposal and the furniture is currently loose (new).

I do not see this being really a large task, with the tools I have at my disposal. Probably the largest task is the helm removal and installation. (Looks modular/Detachable?)

I am trying to plan this all out and I only have weekends and after work time type of thing.

Could it be done in a weeks time after work and over a weekend (~36hours).

Thanks,
Chris

 

[Snake334]

Re: Pontoon Deck Replacement....

You should be able to get it done in a weekend. Once the fence and helm come off, the rest isn't too bad at all. You may have to grind off any broken deck screws, but that's no big deal. When disconnecting the helm, the boat wiring harness is usually modular, but the engine harness is not. The engine harness and throttle and shift cables will have to be disconnected from the engine and pulled through the floor. Once that's done, the rest is pretty easy.

 

[MH Hawker]

Re: Pontoon Deck Replacement....

Use marine grade plywood, 7 layer, the floor is a structural part of the boat not just some thing you walk on.

 

[Solomon_Man]

Re: Pontoon Deck Replacement....

All,
Thanks for the tips!

I already have decided on marine stamped plywood.

This is my second boat redo. Redid a 1959 Lonestar Monterey (late dads) and learned all about the quality differences in plywood. Also on how to get nailed/screwed down old plywood off. Glad I invested in a good whole cutter and quality marine plywood in my dads before re-glassing.

Again thanks for the tips and help,
Chris

 

[5150abf]

Re: Pontoon Deck Replacement....

The problem isn't the carpet or wood, those are the easy parts, to redeck a boat you have to remove and replace everything on the deck, trim console , lights wires furniture , it is a real job just figuring out how to take it apart and then doing it without destroying things.

Make sure you mark every wire with function and place before you pull it, I use a sharpie and a masking tape flag, just fold a lenth of tape over the wire and mark it like "Nav light + top left" so you what and where it goes on reassembly.

If you are really lucky Godfrey used stainless when they built your boat but odds are they just used regular screws so they will all be rusted into the deck and you will have to get them out with out screwing up the furniture console ect, it can be a task.

I gutted my fishing boat and redecked it and every single screw was rusted in and I had to cut the head off and jerk the wood up then cut the screw flush or work it out with pliers.

Not trying to scare you but it is really involved, it is also really cool when you are done then when you are on the boat you will know you built it yourself.

Pay very close attention to how everything came apart to the point of taking notes

 

[5150abf]

Re: Pontoon Deck Replacement....

Just notice the guy saying he is the OP has a join date of Sept 09 and 110 posts and the real OP who started the thread joined Apr 12 with 10 posts, curious .................

 

[SolomonMan]

Re: Pontoon Deck Replacement....

Just notice the guy saying he is the OP has a join date of Sept 09 and 110 posts and the real OP who started the thread joined Apr 12 with 10 posts, curious .................

All,
I am one in the same...one is my tablet and one is my pc.

Again thanks everyone for the comments...I am a engineer by trade and I am considering replacing the helm section either in a full after market one or a custom replacement..,.the design of the helm is basically a square upholstered wood box with a cutout section for tach, steering, odometer, glove box etc.

Labeling and cell phone pics are a standard process...

Thanks again,
Chris

 

[dls322]

Re: Pontoon Deck Replacement....

If you have helpers it will go allot easier. I redid 2 pontoons myself in my driveway. The most difficult removal is the helm. You will need to disconnect the steering cables and the throttle cables. Depending on ther condition of your steering cable might be a good idea to replace it now. Then you have all the gauge wires and such, also have the batteries and the cables to the helm and to the engine. Fuel tank will also need removed. Hardest part of getting the old deck off is how it's attached. My first boat i had to grind down all the rusted bolts. You need to look under the boat to see where they are on the deck, since they are covered by carpet. Depending on condition the carpet can be a bear to try to pull off.
I could go on and on, but there are a ton of writeups online of how to do this. You might be able to tackle the wood floor it in a weekend but it will take months to actually "finish" the boat.
Good luck and have fun!!