Replacing My Deck

[obxhawk]

I am new to this site but have really enjoyed reading through some of the forums. I have recently acquired a 1989 Raven 2100 CC. Overall, it's in great condition and runs well. The deck was replaced about 3-4 years ago. 3/4" pressure treated plywood was installed, glassed and carpeted. Unfortunately I have noticed several soft spots. Not sure if it is rot or just broken because the previous owner was 300+ pounds and used the boat frequently in rough water. I am going to pull the deck and inspect the stringers and transom. I'm hoping that it's just the deck that will need to be replaced. Several people have told me to just replace the deck plywood and then paint it with a rubberized, non skid paint skipping the glass. This sounds way too simple. Any suggestions would be appreciated. Also, if I find that the stringers and/or transom are bad, how big a job is this going to be for someone with basic woodworking/carpentry ability?

 

[Maxum21]

Re: Replacing My Deck

If the floor/ deck was sealed and glassed good, i doubt it would be rotted already. where are the soft spots? maybe its lacking support underneath or not properly glassed to the hull. You really dont know until you start cutting some of it up. Its ALOT of work to do as you mentioned(floor, stringers transom). but if its already falling apart, you might as well either start tearing it up or sell what you have use the money towards another boat.
good luck

 

[obxhawk]

Re: Replacing My Deck

I'm actually looking forward to the project. My only concern is that I could get myself in over my head and do more damage than good. Replacing the plywood deck is not as much a concern as having to replace stringers or worse the transom. I guess my first step is to just jump in and pull out the existing deck and see how it looks underneath.

 

[micks110]

Re: Replacing My Deck

OBX- you are right- you just have to jump in and start taking up the deck. If it is just the deck- I would recommend glassing it in on both sides and then glue it down, screw it down, or glue and screw. This is where I am at in my project now but I had to do it all- stringers, transom, new glass on the hull to stiffen it up, etc...

If it ends up being the stringers as well- it is not that bad. It is alot of work and time but it will be satisfying at the end knowing it is done right.

I used seacast but if I would have used wood for my stringers it would have cut my time in half. With seacast it is a ton of time prepping the new stringers for glass. With wood you can glue down your stringers and glass right over the wood once the glue sets up.

I knew nothing about boats and fiberglass prior to starting my project and I have made it this far

 

[obxhawk]

Re: Replacing My Deck

Thanks Mick. I just read your threads on your restoration. Absolutely amazing. I really hope that my project is not going to be that intensive. It looks like you have gotten quite an education. I'll look forward to seeing how it turns out.

 

[micks110]

Re: Replacing My Deck

No matter how extensive it will be or not, you will learn as you go with the help from these great guys on this site. Dive in and start learning!
Good Luck

 

[MTribe08]

Re: Replacing My Deck

Please report back as to what you find with your deck. I believe it was mentioned somewhere on this board that pressure treated plywood will not rot..would be useful information for those trying to decide what to use.

 

[obxhawk]

Re: Replacing My Deck

I will report my progress. Unfortunately we got a lot of snow this weekend and they are calling for more next weekend so it may be a few weeks before I can really start digging in.
I spoke with the previous owner and was actually 10 years ago when he replaced the floor. The stringers and transom were in great shape then. I pulled the captains seat. It was wobbly. It pulled right out but the screws were rusted through and it fealt more like the deck boards were just broken and not rotted. I pulled back some of the carpet but couldn't see anything other than the glass.
I am really thinking that the deck boards are just plain broken rather than rotted. As I said before he frequently took his 300+ lb. son in law out into rough water frequently.

 

[tmcalavy]

Re: Replacing My Deck

Get a long, small diameter drill bit and start taking core samples by drilling into the deck...8-10 around the whole deck. What comes out? Wet mush or solid wood? If it's mush, you need to pull and replace the deck and maybe the stringers. If it's solid, that BOB (big ole boy) may have compromised the deck here and there. Ten years is enough time for a deck to start in with rot, depends on how it was stored. Core samples will put you in the ballpark of figuring out what you're up against.

 

[obxhawk]

Re: Replacing My Deck

I took the advice of tmcalavy and started drilling to see what came out. Nothing but mush. I tore a hole so I could get to the stringers and there is nothing left. I am amazed that I could even walk on the floor. It's like soggy cardboard.
So my job is looking to be much bigger than I had thought. I've been following some of the full restorations and see that it's a major but doable repair. I am just a little overwhelmed by it right now.
Any suggestions at this point are greatly appreciated. The boat was free. The motor runs great. The outdrive is good. It's a perfect size boat for my area. I guess I'm wondering if it is worth it to take this on or just junk the whole boat now???
Something I need to consider is the cost of this job. Am I looking at a few hundred dollars in materials or is this likely to run into a few thousand?

 

[ezmobee]

Re: Replacing My Deck

What motor is in this thing? Your structural issues combined with an obsolete motor/drive would definitely be a deal breaker. However, if it has a well-supported powerplant (Mercruiser/Volvo), you LIKE the boat and it will meet your needs for some time....then I say go for it. Just make sure you understand that it's an investment primarily in your own enjoyment. You probably won't get out what you put in it although a stringer and deck job done with polyester shouldn't break the bank. Much more time than money.

 

[z284u2try]

Re: Replacing My Deck

I don't think it will cost as uch in materials as in time.
Let me know if you junk that boat.

 

[micks110]

Re: Replacing My Deck

OBX- If your deck and stringers are as bad as you said the next step would be to check the transom out to see if those core samples are bad also.
Like someone else said- It will be more time than money, especially if you just go with ply or 2X's for the stringers.
If you looked at my thread I have a complete restore- deck, stringers, and transom. I am in the hole right now about $1200. $700 of it was for the seacast. If I would have went with traditional wood products I would have been 1/3 of that price or less.
I will be right at about $2000 when I'm all done and that will include new electrical and top and bottom paint. Depending on the cost of my windshield I may go a little over $2000- that's the only thing I don't have a set $ amount for yet.
Oh- hours- I probably have 200 hours into it at this point. It is definitely a labor of love. $2000-2500 done by me on my time beats $10,000-15,000 for a new boat though in my opinion.
Good Luck with whatever you decide to do.

 

[obxhawk]

Re: Replacing My Deck

Thanks Mick. I have been following your progress. Beautiful work. I appreciate your input especially when I see what you have done. I guess at this point I have nothing to loose by just jumping in and keep pulling it apart.
I pulled out more going toward the stern and it's all rotted until you reach the point that was covered by the dogbox and rear seats. Beyond that is the original floor and is pretty solid. I am still going to replace everything.

 

[obxhawk]

Re: Replacing My Deck

The plus side is that everything forward of the cabin bulkhead seems solid. I'm hoping to not have to tear out the bulkhead but we'll see. I also haven't had a chance to test drill the transom. I'm keeping my fingers crossed. So far everything near the stern seems to be solid.
ezmobee: It's a 3.0 Mercruiser and and Alpha One. That's the best part. The previous owner is a mechanic and has kept the engine and outdrive in perfect shape.
Thank you all for your input. I'm going to continue pulling the deck and check out the transom. I'll keep posting here along with pictures. The biggest challenge now is the weather as I am working outside.

 

[BobsGlasstream]

Re: Replacing My Deck

obxhawk,
I'm glad you have decided to join the ranks. The Mercruiser 3.0L with the Alpha drive is a workhorse. I have one myself. It isn't the strongest motor out there but it will last.
I wouldn't hold out to much luck for the transom either. Looking at your pics odds are against you.
Once again, like others have stated It will be mostly time. If deck and stringers are done correctly and then stored correctly, they should last you for a lot of years. Your boat is already 21 years old and I'll bet they weren't done half as good as they will be when you are finished.
Good luck and welcome.

 

[obxhawk]

Re: Replacing My Deck

Thanks Bob. After reading and seeing what you and Mick have done and knowing you guys are willing to give advice really builds my confidence in jumping into this. I hope you are both ok with me asking some rookie questions as I move forward.
Mick, you mentioned you have about 200 hours into your project. I showed my wife the problems we have with our boat and told her what you have done and I thought she was going to lose it. Any advice on getting the wife/family behind you with this much time involved? lol!!!
We are supposed to get a break in the weather here this weekend so I am going to try to get as much of the rot torn out as possible.
I am not sure how everything ties in at the cabin bulkhead. If I have to tear out the cabin, it will more than double what I am thinking needs to be done. If the stringers are solid forward of the cabin, can I tie the stringers back of it in or do I need to plan on just tearing it all out down to the hull so I can run new from the bow to the stern?
Because everything is so rotten, I won't be able to use any parts as templates for when I start replacing the deck or stringers. Is there anything you guys recommend I make notes on, measure or mark prior to just ripping it all out?

 

[MTribe08]

Re: Replacing My Deck

Thanks Bob. After reading and seeing what you and Mick have done and knowing you guys are willing to give advice really builds my confidence in jumping into this. I hope you are both ok with me asking some rookie questions as I move forward.
Mick, you mentioned you have about 200 hours into your project. I showed my wife the problems we have with our boat and told her what you have done and I thought she was going to lose it. Any advice on getting the wife/family behind you with this much time involved? lol!!!
We are supposed to get a break in the weather here this weekend so I am going to try to get as much of the rot torn out as possible.
I am not sure how everything ties in at the cabin bulkhead. If I have to tear out the cabin, it will more than double what I am thinking needs to be done. If the stringers are solid forward of the cabin, can I tie the stringers back of it in or do I need to plan on just tearing it all out down to the hull so I can run new from the bow to the stern?
Because everything is so rotten, I won't be able to use any parts as templates for when I start replacing the deck or stringers. Is there anything you guys recommend I make notes on, measure or mark prior to just ripping it all out?

There really isn't any getting around it, the biggest expense with this job is time spent, and why it costs so much to have done. You can look through my thread and see the job I'm doing, and although it's not near the extent of Micks, I have spent easily 80hrs out there and if your wife isn't on board with the project it could turn into a real mess.

My boat was ok rot wise from the back of the ski locker to the bow. I was lucky because I was in no position to be pulling the cap off. If you have/want to do that, that takes the project to another level.

As far as marking stuff, I didn't, but then again I like you didn't have much to mark. If you leave part of your deck in place you can use that to determine the needed height if your stringers and side supports.

As far as budget, I went with poly over epoxy because if the large increase in price. It's done fine for me. Be prepared to use ALOT if cheap paint brushes and nitrile gloves. Make sure you have a good grinder with multiple flap/hard/ cutoff disks. And a sawsall came in very handy for me.

Good luck

 

[BobsGlasstream]

Re: Replacing My Deck

obxhawk,
Until you get most of it out you really won't no if you can save any of it.
Sometimes you get lucky and will find that the forward section is OK, and yes you can tie into it if it's enough to be worth saving.
You can start making some templates as you tear it apart or take a lot of measurements.
Another way to keep the new deck the same height is when you cut out your old deck at the point were it attached to the hull on the sides. You will need to grind down, Just leave a small amount of it to allow you to see the old deck height. From that you can rebuild the new deck and supports at the same height.
To get the shape of the bottom of the stringer you can just use the post and scribe method. Not hard to do and a lot of examples in the threads on iboats.
Sorry to hear your wife isn't on board with you but should not be a total show stopper, Mine wasn't totally with me either, when she wants me to do something with her I just try to work around it. Hopefully you know how far you can push it.
Don't worry about asking any question either, we will all do whatever we can to assist.
Good luck and look forward to following your thread.
Bob

 

[obxhawk]

Re: Replacing My Deck

Thanks Bob. My wife and I talked about it more tonight. Her concern is that I will get wrapped up in this and not spend time with her and the kids. I suggested we look at this as a family project and all take on parts of the job. When it's done then we can all take pride in the work we have done. I know this is a silly discussion to be having in this forum but something that anyone considering jumping into should discuss with their family because of the time involved. Anyway she agreed.
That said, I drilled several test holes in the transom. The wood was dry and not discolored like the rest of it. I spoke with my buddy who gave me the boat and he said he had the transom worked on about 5 years ago. I am still going to have someone I know from a local boat repair shop come by and take a look. I may have caught a break here. For now I am going to concentrate on the deck and stringers. I won't have to pull the engine or outdrive for that. We'll see.
I took a closer look at the stringers today and was shocked to see that they are plywood standing on the edge and then wrapped??? Is that common? I know it's awhile before I will get to the point when I start replacing them but I would think salt treated 2X would be the strongest and best option.