Wooden Boat Restoration Part 3 New Deck | BRYNHILDE 1958 Fred Parker 10m Bermudian Sloop

The BRYNHILDE Restoration
Refit and restoration of a 1958 10m Wooden Bermudian Sloop, designed by Fred Parker

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Winner of the British Marine Media Innovation Award, recognising work in the field of professional marine media.

Our entry was this video series covering the restoration of a 1958 wooden Bermudian Sloop, captured over 2 years, condensed into 33 minutes over a series of 13 videos.

The videos aren’t just covering the refit, they’re a celebration of everyone who was involved. Without the talented team of Shipwrights, Engineers, Electricians, Riggers, and Painters, none of this would be possible.

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In most cases when renewing a traditional teak deck, a solid plywood sub-deck made of high quality marine grade plywood is bonded and secured to the deck beams, this adds significantly to the strength of the replacement deck, ensures watertightness and also allows the teak deck panels to be laid without any fastenings, further reducing the risk of future water ingress and increasing the life of the deck, as there are no shallow fastening dowels to worry about.
 
The deck planks can either be fitted straight or swept to follow the shape of the gunwhale and snaped into a king plank. Brynhilde originally had a swept deck and the replacement teak panels were set out to replicate this arrangement. 
 
With the new sub deck sitting snugly, it was time to turn them over and begin work on the underside.  This is the expanse of wood that ends up as the deckhead in the cabins below and to avoid the look of a modern ply subdeck the detailing is important.  The individual sections of marine ply were positioned and temporarily fixed together and the traditional swept lines of the original teak deck were set out on the underside. The dummy seams were cut into the underside of the ply panels with a router, which once painted gives the look of traditional deck plank seams from the underside
 With the detailing of the underside of the ply panels completed, the sub deck could be fitted, glued and screwed to the deck beams and carlings, ready to have her new teak deck laid on top.
 
At Berthon we carry out all the work required in teak deck repair or replacement, along with all deck maintenance for boats up to 120 tonnes. We also carry out remedial work on teak decks for small cruising boats including traditional scarfing and caulking repairs. 
 
The replacement teak deck for Brynhilde was ordered from Moody Deck. Fabricated from sustainably sourced teak and assembled in a jig to replicate the curvature of the swept teak deck established from the templates taken by Berthon, the new teak seams are pre-caulked, fitted with a bond breaker tape to avoid seam edge failure and finished off with a glass and epoxy resin laminate scrim to both stabilise the deck panel geometry and provide the perfect surface for bonding the teak panels to the sub deck.
 
The new teak deck arrived in several pieces and underwent a few final stages before being glued to the deck, following a quality control check undertaken by our shipwright foreman; the original templates were overlaid on the new deck marking where any fittings will need to be cut through. The covering boards were added to outboard edges to cap the end grain of the ply sub deck panels and the whole deck was dry fitted.
 
Once the foreman was satisfied with the dry fit, the deck could be lifted and the adhesive application started. Once the adhesive is applied, each section of deck is laid in place and aligned with refence marks established during the dry fit process. Working around the yacht until all sections of the new deck ihas been laid in lace, the entire deck is ballasted to ensure the teak deck panels are fully seated and tany excess adhesive squeezed out. We used 120 25kg weights on Brynhilde and these are left in place overnight as the adhesive cures.
 
Following removal of the ballast weights and a little cleaning up of the margin and covering board seams the next task is to pay up the remaining seams, leaving a seamless joint and a perfectly finished deck. 

www.berthon.co.uk

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Restoration Playlist
   • BRYNHILDE Restoration - 1958 Fred Par...  

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Project Overview
   • Wooden Boat Restoration Project Overv...  

PART 1 - Arrival & Inspection
   • Wooden Boat Restoration Part 1 Arriva...  

PART 2 - Exterior Restoration
   • Wooden Boat Restoration Part 2 Exteri...  

PART 3 - New Deck
   • Wooden Boat Restoration Part 3 New De...  

PART 4 - Interior Restoration
   • Wooden Boat Restoration Part 4 Interi...  

PART 5 - Paint and Finishing Touches
   • Wooden Boat Restoration Part 5 Paint ...  

PART 6 - Launch & Stepping her mast
   • Wooden Boat Restoration Part 6 Launch...  

PART 7 - Sea Trials
   • Wooden Boat Restoration Part 7 Sea Tr...  

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Deck Teaser
   • COMING SOON The BRYNHILDE Restoration...  

Paint Teaser
   • COMING SOON The BRYNHILDE Restoration...  

Launch Teaser
   • COMING SOON The BRYNHILDE Restoration...  

Mast Stepping Teaser
   • COMING SOON The BRYNHILDE Restoration...  

Sea Trials Teaser
   • COMING SOON The BRYNHILDE Restoration...