Getting ready for deck painting

During the last month of boat works I focused on preparing the deck for painting, a job that shouldn’t require a month of full time work. In reality, this task is much more than sand the old paint off and clean the surface.

The job can be summarized by this sequence:

• sanding
• fiberglass jobs where needed
• more sanding
• more fiberglass repairs
• fairing
• more sanding
• more fairing

Do, repeat and loop the sequence to one’s own standard of “ready to go”.

A “detail oriented personality” could go ahead in an obsessive and repetitive challenge until the fingertips will be scratched to the bone  before considering the deck ready for painting. Luckily I am not that kind of person. On the other hand I am a victim of creative ideas randomly rising  during the progression of the project. This modifications sometimes put a heavy hand in the plan, disrupting it totally.

Deck modifications

Before a thorough deck preparation could start I had to complete few design ideas that would help solve some issues we experienced with the original deck layout.

Columbia 29s were built with an interesting deck to hull joint that rises few inches above the deck to form  bulwarks from aft to end. This was also the designer’s signature to give a very nice sheer line to the deck. We love the bulwark on Tranquility, they help keeping your feet on deck when the boat heels as well as providing a barrier for objects that wants to fall overboard.

The drawback is that mooring lines and other overhanging hardware have to climb this protective wall incurring in the risk of chafing or making their installation difficult. This is particularly true on the bow, where the anchor roller and other deck hardware had to rest on a precarious base made of untreated construction grade lumber that obviously had rotted away and became a condo for photophobic insects by the time we owned the boat. Shame on whoever cobbled up that ridicolous solution!

The problem had to be addressed with some creativity and a lot of courage. When it was clear that Tranquility required a “nose job” I went through the anxieties and insecurities common to pre and post plastic surgery. With a heavy hand and a heavy heart I pressed on the angle grinder cutting away inches of fiberglass, trying to draw a symmetric line.  I then composed a base layer using several odd shaped teak hardwood pieces, put together with thickened epoxy and fiberglass.

This slideshow requires JavaScript.

Olin Stephens may be turning in his grave for the new line of his design but the occasional Yacht Club guests walking by were actually pleased with Tranquility’s new look. Our friend Brian even ventured in calling the new look “race boat like”.

Similarly I did a little modification on the transom corners to create a better surface for hardware and mooring lines.

This slideshow requires JavaScript.

Stanchion bases

Raised stanchion bases were another upgrade we thought would improve Tranquility’s deck. A thicker and wider base would help preventing stress cracking from wobbling stanchions and keep their base raised from water puddles.

After laminating few layers of biaxial fiberglass tape I cut the stanchion base a little wider and then glassed it permanently to the deck.

This slideshow requires JavaScript.

New toe rail

The original toe rail was made of three pieces of teak forming an overturned U on top of the bulwark and it was  fastened with bronze screws. Age and damages had reduced the coverage and efficacy of the teak toe rail. A recent experience during a delivery raised curiosity towards the hull to deck joint on our boat and so I had to get the wood off and expose the joint. The removal job was one way and I knew that after that I needed to give Tranquility brand new toe rail. I fancied a project featuring  fancy solid teak bar bent in shape over the bulwark but after realizing that I purchased a not so great stock of teak hardwood from E-bay I had to reconsider the idea. You get what you pay for they say, so I opted for using that wood to create permanent epoxy and fiberglass toe rail that will be painted with the deck.

The project include around 100 stainless steel #8 sheet metal screws (one every 8 inches) to join the inboard and outboard teak strips as well as a huge amount of epoxy and colloidal silica and fairing compound as additives. A 6 inches fiberglass cloth was wrapped around the edge and the overhanging extremity sanded off after the resin cured.

This slideshow requires JavaScript.

Sanding

Every project had its own portion of sanding so soon Tranquility’s deck became a patchwork. But for our particular paintjob we had to remove any trace of the one part enamel paint we used in our first refit in New Bedford MA. After giving one part paint a try we decided to go with two part that is supposedly harder and more resistant to UV action and wear. To do so we have to remove any trace of one part paint first, as it would not stand the aggressive solvent of two part epoxy primer and polyurethane topcoat and flake off ruining the paintjob.

That required a lot of scraping that we diligently executed using wood chisels. With Kate’s help we went around and scrape it all off, revealing a calico pattern formed by several layers of paint, from the original gelcoat to more recent epoxy primers.

While operating the chisel closely to the deck I also exhumed several fiberglass delaminations deeply buried under fairing compound and primer. A delamination happen when two layers of fiberglass start to peel apart from each other leaving a “soft spot”. Everytime the first reaction was to turn my head away and say we would live with it. But I always succumbed to the temptation of fixing them and make the deck stronger. After all how bad could it be another fiberglass job?

This slideshow requires JavaScript.

Going through al these pictures I see what I spent the last month doing, and I feel a little less bad about my progress. The deck is not painted yet though and right now we are dealing with our own level of perfectionism and waiting for good weather. Meanwhile: do, repeat and loop.