Teak Decks, Cabin Sole: Construction and Installation

Methods and Techniques

There are traditional laid teak decks and a more modern method which involves vacuum bagging new decking panels over an existing deck .  When Emerald Marine employs the modern technique, we  construct our panels made to patterns from the boat in our shop. We have also installed panels made by Teak Decking Systems and employ their products in making our custom panels.   Boats we've decked include a Grand Banks '36, a Northern Marine '64, and a long distance steel cruising yacht, built on an extended tuna fishing hull.  As seen at the bottom of this entry, we have also constructed a custom teak and maple cabin sole for as part of a custom interior on a  37' Nordic Tug.

Here is a panel  laid up on scrim. The seams will be filled with black caulk and  sanded before taking it to the boat

The finished is panel ready for installation

These decks were laid on plywood while in the shop
replacing the original Grand Banks construction

The Grand Banks bow showing the seams of the panels
under the margin boards beneath the cleats

Here a panel has been installed.
The adjacent area prepared for the next 'bag

Vacuum bagging technique set up

Ready for final caulking
between the panels and the covering boards

For the cabin sole of Gandalf, a 37 foot Nordic Tug, Emerald Carpentry's James McMullen skillfully constructed solid tongue and groove teak and maple flooring and carefully fit it around furniture and hatches.