WE SAVED 40k and OUR TEAK DECK! | DIY Teak Deck Restoration... Ep 354

Our teak deck had seen better days, and after over two decades of use, it was time for some TLC.

The 3 Options

We were faced with three options: the first one is to completely rip up all the teak and replace it. The second option could be to rip up all of the teak and then fiberglass it in, and put a nonskid over the top.

The DIY Project

Ultimately we chose to refurbish the deck, working out cheaper and easier. With an initial estimate of over $40,000 for a full replacement, our budget-minded approach allowed us to carry on sailing and living aboard as we worked.

The Tools Used

• Sander (80, 120-grit)
• HK tools teak deck plugs set of 300 (various sizes)
• Epifanes epoxy repair kit to fill holes and bungs
• Squeegee tool for applying corking to seams
• Bosch MX25 multiplus impact driver, used for drilling out old screws and driving new ones in place
• Tek deck systems sis 440 corks from 3mm to 6mm
• Asetone for cleaning up the deck before corking application

The Process in Detail

It took months of painstaking work, drilling out old screws and capping the holes. 1034 screws were removed, holes filled with epoxy, capped, sanded down, then it was time to apply the new corks.

Prepping The Deck

We removed all items on deck, pressure washed and cleaned it. Then we sanded everything down to prepare for the new corking.

The Final Sanding

We were determined to get a perfectly smooth deck and went over it again with 120 grit sandpaper before applying the corking.

Applying The SIS 440 Corks

Using a technique of no taping, we applied the sis 440 corks to the seams and let it cure. We used acetone to clean all debris out of the seams beforehand for proper adhesion.

The Result

We are overjoyed with how our new corked deck turned out. It looks brand new and is so much better than the expensive quotes we received for replacements.

Save Up to $40k

This project saved us a massive amount of money by doing it ourselves. With just our time and elbow grease, we turned a 20-year-old teak deck into something stunning without the hefty price tag.

Maintenance Tips

Looking for some tips on how to maintain your new corked teak deck? Keep an eye out for any loose screws or plugs, and keep the area free of debris. Regularly cleaning and protecting with appropriate products will help ensure your corking lasts as long as possible.

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