New Deck, Part 1

I finally decided to have the 24 year old 2-level deck replaced.  Even pressure-treated wood doesn't last forever.  I had gotten estimates last Fall, but put off doing anything while I decided whether or not to rebuild it myself.  After all, I built the original, 200' of 6' tall fence, a toolshed, and framed raised beds.  But on my birthday in May, I concluded that:
1 - I'm not 40 any more
2 - I can do rough carpentry but not nice design work
3 - After treating the house to new siding and shingles, why build another ugly (but functional) deck
4 - I could afford to have it done by professionals

So  yesterday, I removed everything from the decks, and closed the container plants (lillies and caladiums -bad for cats) in the catroom.  This morning, I closed the cats in the bedroom,  and the people arrived to tear down the old and put up the new.

Well almost.  I knew they would do the demolition today and build the new deck Monday.  Except I didn't quite ask the right questions about the schedule.  They will START building the new deck Monday.  Monday is for digging holes and laying in footers for the posts to rest on (the old upper deck was 12'x12', the new one will be 16'x16' and there will be no lower deck).  Tuesday will be for the County to approve the footers.  Then on Wednesday and Thursday and possibly Friday they will actually build the new deck.

The cats are horrified and I'm not thrilled either.  I thought they would simply build the entire new deck.  It only took ME a week to build the existing one by myself!  Oh well, "this too shall pass"...

While I'll put together a whole demolition-to-completion post at the end of the project, here are a few demolition pictures:

The original, with all the furniture and stuff removed.

The demolition begins.

Down to the joists.

Nearly gone.

It all fit into 1 trailer.

And the demolition is complete!  And BTW, for some reason, the new green siding always looks blue in my photos.  The old ledger board is left in place for now to keep hot air and wasps from getting into the basement through the bolt holes.

I sure hope it doesn't rain next week to delay things further!

Deck

Well, I had a deck builder come by yesterday to discuss replacing the old deck.

When I moved here 27 years ago, one of the first major things I did was build a 2-level deck.  The main floor had sliding glass doors 10" above ground level and a pre-made fence section nailed across the outside so that no one could accidently open the doors and fall out.

But below that was a sunken patio with a cinder block wall around it.  So it seemed like a good idea to use the cinder block wall to support deck posts, and I sort of wanted to use the sliding glass doors for "something".  I bought a book on building decks, designed one, ordered the lumber for delivery, and recruited a friend and a friend-of-that-friend to help.  I'm a by-the-book builder.  I follow "the rules" (Dad was an engineer, and certain habits get passed along).  Like bracing posts using small boards to anchor the posts.  The friend had the carpentry skills of a hippo (zero) and his friend was a "just do it fast" type.  It was not a good combination.

But it worked out OK.  They did the initial cutting away of some vinyl siding (I couldn't watch that part)  and heavy lifting to get the ledger board attached to the house.  I did all the rest myself so I could do it "my way").  Even today, the deck guy pounded and jumped on the deck and said it was still "damn solid".  But even pressure-treated wood does not last forever, the deck was never build "to code" (I had no idea there were codes at the time), and it is ugly as hell.  You can build something to engineering specifications and still have it "ugly".  My artistic skills are not outstanding.  If I had design physical things for a living, I would starve to death.  Let's just say that if life was a ballet, I would be a hippo!  My constructions are very functional, but that that's about it.

Plus, it is a 2-level deck.  The higher level is 12'x12' and the lower level 12'x16'.  I had in mind throwing parties in my new house.  I learned I couldn't fill a closet with "friends" and I'm am not a party-thrower...

So the new deck will be a slightly larger upper one and no lower deck.  The new 16'x16' deck will have very sturdy composite flooring (it used to be cheap and flimsy, but the current stuff is as solid as real '2" by 'wood, and will last longer than I will.  And it is colored right through, so no staining required. 

It will take a several weeks for the deck guy to get the building permit, which is good because it gets me past my dental work next week and also into the drier time on the year (the front yard is muddy in April/May and it is a LOT easier for him to bring the lumber into the back yard by small truck).  I can't wait.

BTW, I mentioned only one builder.  I'm good about competitive bids.  I had 4 estimates last Fall.  So I took the one I preferred among those and asked him for a revised estimate.  Since the revised estimate was so close to the previous one (even with a couple of changes) I just accepted that one.

Decks and Other Constructions

Previously, I mentioned construction failures.  Today I show successes.

The small rail is now firmly attached to a metal brace...

The corners are seriously attached with pocket hole screws!

The top rails are solidly attached with 3"deck screws...

And I am fighting the warped deck board with a soaking towel. 

My strongest clamps are not sufficient to force the warped board down flat, so I am using water to encourage the board flat...  Water on the top should force the board flat again.  And then I will keep that board there with several 3" deck screws.

I'm close to rebuilding the 20 year old deck, but there are good reasons to maintain it "tolerably" for another year...

Repairing the Deck

I've been annoyed at these deck failings for a decade.  I thought of attaching splines or Dutchmans to the corners. I didn't like the idea.

Then, a few days ago, it occurred to me that I had bought a Kreg pocket hole jig a few months ago for building a table.  I decided to look and see if it would work on the deck.

It did.  Without any experience at it, just briefly skimming the instructions, it was all obvious.  The one thing they fail to tell you is how to remove the clamp platform (you slide it towards the back and it releases upwards).

I attached the several top rail corners with the pocket holes  I was AMAZED!  Only 2 screws in each top rail connection and the entire top rail was as solid as steel!

Call me stupid for not taking "Before" pictures of the high deck rails.  I too often forget to take "Before" pictures when starting projects.  But here are some "After" pictures.


Here's the "stuff" I was using...

Here is the pocket hole jig...

Here is the nicely joined corner of 2 top rails...

Here are the pocket holes.  They weren't perfect cuz it was my first time and the clamps on it were hard to arrange.  But these pocket holes pulled the joints up tighter than any box or finger joint.  They were SO rigid, that I could not make them shift slightly in ANY way.  WOW!  You HAVE to try this!

Next time, the lower deck with it's own unique problems...

Decks and other Constructions

I will say straight out that I am a very functional structure-builder.  By that, I mean that nothing ever falls (my friends say I seriously overbuild everything).  But it is never especially pretty.  I don't have the artistic skills to make visitors say "Oh what a lovely deck".

My simple goal is that anything I build be functional and durable.  Artistic comes in last place.  If the deck stands rigid while 20 people are doing a conga line on it, that is a successful deck to me.

I mention this to explain my latest project...

The foundations of the deck are solid.  There are angular braces that make it rock solid; I have more of those than any deck needs, but more is better than less.  The foundation of the deck is is made of exterior glue, 100's of deck screws, 6" lag screws, and 8" carriage bolts.  But the less structural parts are weak.  I had no training at it, and there were errors.

The top rails are wide and flat (the better for leaning on).  For example, I would never use nails again, but deck screws instead.  But I attached the top rails to the posts with simple nails.  20 years ago, I did not realize that heavy boards would move.  I know better know.

Over the years, the toenail connections of the top boards failed, some deck boards warped up, etc.  I decided I needed to either completely rebuild the top or repair it.  I decided to repair it,  The deck itself is a solid as a cement base.  I think I could drop a car on it without damage.  But the top needed repairs.  The side rails and the front rails had completely disconnected.

Corners of the top rails had separated after 20 years and the top rails wobbled a bit.  Some deck boards had warped up pulling the nails loose.  Some deck rail tops were twisted.  Nails were coming loose

Here are examples:

Tomorrow, I decide to get at "Fixing It".  Time to take action...