simulated plank decks

[redagain]

Im restoring a 57 cavalier. The front deck is just one huge expanse of mahogany plywood. Since Im not concerned with keeping it completely original. Is it possible to cut simulated joints in the plywood deck, then caulk em up with the white stuff, Thanks

[Jay Greer]

It's done all the time.
JG

[redagain]

Thanks JG, whats the best way. Im sure with a guide, but router or saw. Im alittle new to wood working on boats.

[mcdenny]

A little circular saw will chip the top veneer of the plywood. Use a router.

An even better, but of course harder, solution would be to epoxy thin (1/8" - 1/4") strips about 2" wide to the plywood, then use either epoxy with graphite or miracle deck seam filler between the strips.

The plywood grain will continue from one "strip" to another, kind of giving away your shortcut, if that matters. Also cutting all those grooves in the plywood will increase the chance of some delamination.

[Bob Perkins]

If you are cutting the plywood deck before installing it on the boat, pre-cut the slots with a table saw. That would be the simplest method. Use a zero clearance table insert to reduce any chipping.

Then some Sikkaflex in the seams to simulate the original deck caulking. (I think it is Sika 491). Don't caulk the seams until after you have stained and varnished the deck in place.