How To Re-Deck A Pontoon Boat

 

Re-Decking Your Pontoon Is A Fairly Simple And Straight-Forward Process If You Do The Following:

• Use high quality marine re-decking grade products, like our pontoon boat floor replacement kits.

• Have a dry location to put the deck and vinyl/carpet on. The deck must be completely dry for the glue to adhere properly

• The glue must cure above 60 degrees for 24 hours

• Installing vinyl/carpet on a lower humidity day will speed the curing process of the glue

 

Before You Start To Tear Your Pontoon Down:

• Take a lot of pictures to show later where everything is located and routed

• Draw a diagram with precise measurements…a few extra minutes here can keep cables and wiring from falling short when you reassemble

• Take measurements of where the railing is located on the deck

 

After Removing The Furniture, Railing & Deck:

• Replace the under-deck wiring. After the wiring has been moved around, any place you have connections under the deck is likely to be corroded, not making a good connection anymore. Save some headaches down the road and replace it all

• Running the wire now will allow you to make sure all rub points are properly protected, and will be easier to work on

• Check all your under-deck hardware and make sure it is tight.  Be sure to pay close attention to the transom area, as it is where most loose bolts are found

• Look your cross-members over and make sure they are in good condition

• Look over the welds on the tubes, finding a crack now will ease the repair process

 

When Installing The New Deck:

• Lay all the sheets of plywood on the deck, making sure they are square and properly centered on the cross-members

• Snap chalk lines where you will be installing fasteners

• Install the fasteners in the plywood on the cross-member where the plywood is NOT butted together first.  This process will help you to make sure the plywood does not move when you install the fasteners on the joint

• If you are using elevator bolts, use at least three on each cross-member where the sheets are butted together and two on the center cross-members.  Adding more elevator bolts is better

• If you are using self-tapping screws, use at least six on each cross-member where the plywood is joined together and five on the center cross-members

 

When Installing The Vinyl/Carpeting:

• Roll out your new marine vinyl/carpet back to front on a clean and dry deck to ensure the vinyl/carpet is the proper length, roll up the vinyl/carpet straight and set it aside

• Using a paint roller with a 3/8” or deeper nap, apply white glue onto your deck.  You MUST apply an adequate amount of glue.  You MUST wait for the water to “Flash Out” * of the glue before applying the viny/carpet to the pontoon boat decking.  Failure to give adequate time for the glue to “Flash Out” will cause the glue to not cure!

 * When the glue becomes “tacky” to the touch, but before it becomes clear, apply the vinyl/carpet. The cooler the temperature the longer this will take.

• Lay the vinyl/carpet down starting at the rear of the deck (the edge of the carpet should reach the edge of the wood.)  Roll it out straight and flush with an edge.  Keep it tight as you roll it out.  If you have any wrinkles, work them out by pulling with your hands to the front

• Staple the vinyl/carpet across the back, keeping to the edge so the staples will be covered by the aluminum edge cap.  We recommend stainless steel staples, if available  

• Go to the front of the deck and pull the vinyl/carpet tight.  When everything looks straight and flush, roll a roller over the entire vinyl/carpet to ensure complete glue-to-carpet contact.  While a floor roller is the best tool, other round items from the garage or even the kitchen (a rolling pin) will work 

• When you are finished rolling your vinyl/carpet, staple the rest of the edges and trim off any excess tight to the edge of the plywood 

• Please do not allow your freshly carpeted deck to get wet or rained on for at least 24 hours (longer if done in cooler weather)**

 *The vinyl glue that we sell is formulated for Syntec marine carpet.  It assures you of a quality product with no worry of chemical compatibility

**Please read the information specified on your glue container

 

Reinstalling Railing & Edging:

• This is where all those pictures and dimensions you took earlier will pay off 

• Install the edge cap on first. This will ensure your railing is located properly as it is easier to measure from 

• Set the entire rail on the deck and get it aligned and in position, then clamp it place so it does not move when drilling the deck for the new fasteners. This would be a good time to set the furniture back on the deck and double check fitment before you drill holes in the deck for the railing

 

Installing The Furniture:

• Set all the furniture on the deck and fasten it down. Using new stainless fasteners with fender washers is recommended

 

Closing Note:

• After reinstalling the steering and throttle shift cables, re-inspect your pontoon, to make sure that everything is working properly before you launch…this is a safety measure