DIY: REBUILDING THE REAR DECK

Our third major rebuilding on Thunderbird was the rear deck.  A few years after purchasing the boat, we came to the realization that the back deck was in really bad shape.  In fact we didn't really know how bad it was until we started to pull it apart in the fall of 2006.  Then we realized we are lucky someone hadn't fallen through it when boarding. 
 

 

The rear deck is completely exposed to the elements at all times.  I was also using a couple of old cushions that I had made from salvaged material from the original V berth.  They were quite heavy, not water proof and a nuisance to have to store inside when it rained.  So we gave a lot of consideration to how we should rebuild and improve it.  The original structure was built with 2X4s and plywood and had lasted since the mid 70s so we could rebuild it as it was originally designed and it would out last us, but we decided to see if we couldn't find newer longer lasting materials that would not need as much maintenance.  I also wanted new cushions and a way to keep them dry without bringing them indoors, to clutter up the interior, when it rained. 
 

We were able to track down new structural 2X4s made of recycled plastic and a 4X8' sheet of 1/2 inch sheeting material called "Star Board", that is just like kitchen cutting board, plus sheets of ridged fibre glass.  All products that would be maintenance free. 
 

Next came the deconstruction.  As we removed each piece of the old deck of course we saved it and put it aside, as templates for our re-construction.  It's a rather complicated structure, that we never would have been able to come up with on our own, so we were grateful for patterns.  As we deconstructed deeper and deeper, we realized how dangerous the original structure had become.  Some spots were mush.  By the time we had removed everything that was rotten, the back wall of the boat was wide open.  The inside of the broom closet was exposed, the compartments under the dinette were wide open and rear door sill were totally removed. 

 

 

 

So, in the spring of 2007, we started the rebuild.  We made some minor adjustments to allow for easier access to fuel tank and steering mechanisms and moved our electrical connection but other than that we rebuilt it as originally designed with all the new materials.  The framing was the new structural 2X4s.  The seat, steps and compartments were all built of star board.  The rear wall was rebuilt of plywood, then laminated with rigid fibre glass. 
 

We got it totally deconstructed and reconstructed in one fall/winter/spring session.  I still had to use the old cushions for a year or so, but now I have made all new cushions and a run-off cover for them so that we no longer have to bring the cushions indoors, to take up space when it rains. 


 
We have also installed a gas Bar-B-Q, which I have made a matching cover for.  I love it. 



And I'm sure it will all last longer than the 30 years the previous deck lasted. 
 

 





SO PRACTICAL WHEN IT RAINS.  I LOVE IT.

ANOTHER REFIT PROJECT WE HAVE ACCOMPLISHED, THAT WE ARE VERY PROUD OF