The first project on the Reel Fishing project boat is to replace the front deck.  There are a few bad spots on the main floor as well, but we’ll get to that job later.  That might be a project for when the boat is stored for the winter, so for now we will show you how to patch the bad spots on the main floor to get you out there on the water.

Like I said before, the man who originally owned this lived in Cleveland, Ohio, only a few minutes away from the launch ramp on Lake Erie.  I’m sure it was nice to be that close to the lake, but for this boat it made some trouble.  We bought this from the owner’s wife.  He had fished in it up to last October, and she said that by December 1^st he always had it all cleaned and ready for the winter.  Sadly, he passed away in early November of last year.

The front deck has the worst damage, so that is what we will tackle first.  There is considerable warping to the deck, and it has separated from the tight fit it once had.  It warped so badly that the owner removed the seat support so as to not forget about it and fall through the deck.

Warped Deck

The first step is to remove the rotting carpet, so that we can get a better look at the bare deck, which is in very sad shape.  It also looks as if it was rebuilt once before.

All the screws and clips from the side brackets need to be taken off, removing each piece of wood as it comes free.  My first thought was to use the old boards for a pattern, but a closer look showed the miscuts from the last re-decking job.  So we opted to make a new pattern using cardboard.  (Tip—use a thin cardboard, it is easier to form and cut.)

Cutting

After taking measurements and laying out a rough outline, we started to cut the first shape out.  This does not have to be perfect, as all it is designed to do is get you closer in the right area and basic shape.  Once that is done, you place the back in place where it is supposed to be, and lock it in with a clamp.

Then, you press your way around the entire deck area a little at a time, beginning with the sides, cutting and trimming with your box cutter knife, and working your way around the entire deck area.  Once that is done, duct tape the cardboard in place and check it again to make sure it is right.  You do NOT want it to be a tight fit, as you will be adding carpet to it once it is ready to install.  We left about a ½” gap all the way around the pattern to allow for this.

Cutting

Next, place the cardboard pattern out on your new ¾” plywood and trace it out.  If it is the way you want it, go ahead and start cutting with your saber saw.  Go slowly so that you do not get off track, which is easy to do!  This does not have to be 100% perfect, as the carpet will allow you to make a few mistakes.

Once the shape is cut out, you are ready to do a test fit, keeping in mind that some trimming may still be needed at this point.  Remember, you want the new deck to lay flat on the supports, without putting pressure on the sides of the boat.  So just walk around, looking and trimming as needed.  Once it is right and you are happy with it, go ahead and mark any openings you may need for storage, hatches, livewell cover, etc.  Remember, measure two (or three or four) times and cut once!

Drilling

Now that you have everything that you need marked on your deck, you can get your drill and make a hole on the INSIDE of each corner of your marked-out area, so you can get the saw blade in.

When you are finished with that, you can get a vibrating sander and sand the edges smooth and even bevel the bottom edges of your outlined deck.  Do another test fit, and look over the openings and edges so you are absolutely sure everything is right.

Sealing

The next VERY important step is the water sealer.  Properly sealing your deck will help it last much longer than if you left it untreated.  I like to coat mine over a two-day period and let it dry in the sun for one day.  Make sure you cover the entire deck, the edges, inside the cutouts for the hatch/livewell, everything!  This is crucial to make sure you have 100% coverage over the complete deck.

Livewell

After the wood is dry you can install any hardware you might need.  For this boat, we have a livewell cover and a door that we cut in for under-deck storage, so piano-style hinges were installed.

When all that is done, test fit it one more time, just to be sure.  You might be surprised at the things that can happen that you might not be aware of, so that when you go to put in the finished deck it is completely off!  So again, after it is right and you are happy, you can remove the deck and get it ready for the glue and carpet.

Preparing To Trim Carpet

An important note...take the time to buy the glue spreader.  It is not that expensive, and it will ensure the proper amount of glue to hold the carpet.  I went with the actual marine grade carpet from Lowes, and I used all black instead of the gray/black.  Once I do the main floor later on, I will do the entire boat in the all black carpet.

Trimming Carpet

Lay out the carpet and trim it a few inches larger than your deck.  You want to leave enough so that you can wrap the carpet around the outer edge of the deck.  Cut out the areas for the livewell/hatch as needed, and cut the hole out for the seat bracket.

Applying Glue To New Deck

Now that your carpet is ready and trimmed, go ahead and spread the glue over the entire deck area, including the outer edge.  Once that is done, place the carpet over the deck.  Starting from the middle, work your way to the outer edges, making sure that every cutout is lined up and everything is right.  Have one side of the carpet started on the edge and staple it in place.  Have a friend pull on the carpet from the other side, making it tight, and start to staple your carpet up along the edge.  Remember to check the cutouts this entire time over and over again as you move around the edge, to ensure they are properly lined up.

Drying

When that is all done, I take another piece of wood and lay it over the carpet, clamping it down all around.  I then leave it overnight to make sure the carpet stays nice and flat as it dries.

Installing New Deck

The next day, unclamp the board and install your deck, screwing it into the deck holders.  If you did it right, it will look like a professional job and something you will be proud of that will last for a long time!

Rebuilt, Recarpeted Deck

See you out there...

gunner