Ron visited the Pacifica home of John and Brenda Hall. The damp ocean air of this costal suburb of San Francisco has taken its toll on their backyard deck and they would like to replace it. Ron helped them replace the redwood with a new decking material that is made from, among other things, recycled plastic bottles. This deck should last nearly forever, even with the ocean spray.
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For a list of what you will need in order to complete
this project.
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a full video of this segment.
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1. Remove old deck boards
Getting old deck boards up can sometimes be a challenge. If the boards were originally put down with screws, use a screwdriver to back the screws out of the wood before removing the boards. If, due to rust and age, the screws do not come up easily, see Ron's tip on removing stripped screws.
If the screws have rusted so badly that they cannot be removed without breaking, those boards can usually be pried up fairly easily and removed. |
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2. Joists and posts
If the decking joists and posts are in good shape, then they can be reused. The composite decking boards that will replace the old boards require that the joists be spaced no more than 16 inches on center. If the existing joists are set further apart than this, an additional joist will have to be added between each of the existing joists. If adding new joists is necessary, you may need to install a rim joist around the outside of the structure.
A pressure-treated 2 X 6 can be nailed onto the ends of the existing joists to create the new frame. Attach the rim joist with a nail gun.
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| For larger decks, an additional 2 X 6 may need to be installed under the existing joists in the center to support the new joists. Hold the support rail in contact with the bottom of the existing joists then nail it to the sides of the posts. |
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3. Attach joist hangers
Center each metal joist hanger between the existing joists and then attach it to the rim joist with rust-proof galvanized hanger nails.
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| Use a hammer to tap each new joist into place so that the top is flush with the existing joists and rim joist. Toenail guides ensure that the nails are driven in at exactly the right angle to secure the new joists in place. |
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4. Handrail posts
The railing posts are supported with railing post brackets, which should be mounted on the inside of the rim joist. First align the bracket and mark where the bolts will be attached. Drill four holes through the rim joist and then tap a bolt through. Slip a washer and nut on the end and then partially tighten the nut with a socket wrench. |
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| Next, position the post through the bracket and finish tightening the bracket around the the post. The railings are installed after the decking is attached. |
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5. New decking
The new decking, called composite decking, is made from recycled polyethylene plastic and recycled wood from woodchips and sawdust from furniture factories, etc. It never needs painting and it lasts virtually forever, which is especially important when installed in areas with harsh weather conditions.
6. First plank
The first plank is often one of the most challenging because it generally needs to be notched to fit around the railing posts.
Use a straight edge or combination square to transfer the angle of the post onto the plank.
Create a template that is the same width that the notch will be and then lay that up against the other side of the post and draw a parallel line.
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| This should leave you with the outline of the section that will need to be removed. Cut the notch section out with a jigsaw. |
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| Clamp the first plank in place before attaching it to the joists. Slide the second board down until it is even with the first board. Where any two boards meet, it is important that they both rest equally on top of a joist. Cut each board so that the end falls right in the center of the joist. Using a speed square as a guide, cut each plank to length with a circular saw. |
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| Before screwing the deck boards in place, lay down several more rows using wood shims to keep the spaces between the boards uniform.
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7. Attach decking
The decking can be attached using any type of power screwdriver
but an auto loading screw gun enables you to do the work while
standing, which makes the job much faster and easier. The
screws come collated into strips so that you don't have to
reload them often. The screws have specially machined ends
that actually help bore a hole, they are both galvanized and
coated making them rust resistant, and they have a small finish
head with a square drive so they are almost invisible once
they are driven in. For more information visit the QuikDrive
website.
Position the drill directly over the joist and push down. The screw drives in quickly and easily. Continue cutting and laying several rows at a time before attaching them with the screw gun.
After all of the boards are attached, trim the uneven boards with a circular saw.
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8. Hand rail and balusters
Slip a prefabricated post base over the top of each post and slide it down to the deck surface. A railing piece called a universal railing is used for both the top and the bottom railing and it is made to fit into the recess in the post. |
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| The universal rail rests on top of the base pieces. Center a short piece of stock directly under the bottom rail and screw it in place for a center support. |
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| Install the brackets that will secure both the bottom and top rail to each post.
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