DIY Synthetic Teak

Hurricane

Well-known member
Joined
11 Nov 2005
Messages
9,393
Location
Sant Carles de la Ràpita
Visit site
First some background on the subject

Please note that these notes are my views and experiences. Not everyone agrees with my views of real wood teak. But, for the last 15 years, I have owned two boats fitted with real wood teak. For me wood teak is just plain “dirty” and needs continual cleaning to make it look good. We spend quite a bit of time at anchor and we don’t have a water maker. So, every morning, SWMBO and I try to get up early enough to catch the early morning dew to “flunky” off the boat. It is then that you see just how dirty the real wood teak gets. Simply stepping of recently cleaned teak onto a GRP coach roof will leave dirty footprints. This dirt is then transferred around the rest of the boat. The only way to clean it is with the two part chemicals. Some yachties will tell you that all you need to do is throw a bucket of sea water over it but that is total rubbish. Wood teak is just plain dirty and slopping some sea water over it does absolutely nothing. Also, over a period of 10 to 12 years, wood teak requires replacing anyway. Princess yachts start with 6mm thick teak decks. After 12 years the teak ends up less than 3mm thick.

Here is a pic showing the thickness of our old wood teak. You can see just how thin it is.

serve.php


About three years ago, the bathing platform on our Princess 67 was showing signs of wear to the point where the black caulking was down to bare wood. This made the whole boat look shabby. So we decided to pay to have it replaced professionally. We chose to fit the second generation Flexiteek synthetic deck so now we have experience in both synthetic and real teak. Everything in boating is a compromise and teak decks are no exception. Real wood is hard to keep clean and wears away whereas synthetic teak gets very hot in strong sunshine but is dead easy to clean. So it is a matter of what suits you the best. In my opinion, the hot summer surface is a small price to pay for dirt free decks thus keeping the rest of the boat clean. Incidentally, away from the marinas, the synthetic teak stays much cooler. And as long as you select a recognised product, synthetic teak can look to the untrained eye just like real teak.

Here are some pics after our bathing platform had been fitted with Flexiteek. Sorry about the state of the old winter cockpit covers in the photo!!

serve.php


Can you tell the difference between the real teak and the synthetic teak?

serve.php


And here you can see at anchor in the heat of the sun that the surface temperature isn’t that bad.

serve.php



So, having had some success with the bathing platform, I now want to do the rest of the boat. Apart from being very expensive, it is important to do the job properly to make it look as close to original teak as possible. For example, planks have to line up as they cross over hatches otherwise the job will look awful. So, after getting some quotations for the work and discussing the techniques with professional suppliers, I decided to make and install synthetic teak myself. The first problem that I ran into was finding a supplier who would, not only supply me, but someone who I could call for advice. These days, the market seems to be cornered by Flexiteek and Permateek who push you to their contractors/dealers. This is not what I was looking for. Eventually, I found Trakmark who specialise in providing the components and materials to do exactly what I wanted.

I have decided to split the rest of my teak update into three phases. For right or for wrong, I decided to do the foredeck first. That has been successful so my next area is the replacement of the flybridge teak and finally the last phase will be in the cockpit. I expect to draw this out over several years. It is a real shame that we didn’t have synthetic teak installed on the boat when she was new.

Whilst researching, it was very apparent that there are lots of ways to design wooden style decks. Looking round the internet, I found some examples of Princess Yachts that had been updated with synthetic teak. In fact I was lucky enough to find photos of Princess 67 like ours. So using these images, I decided how NOT to do the update.

Here is the foredeck of a Princess V where, IMO, they have tried to follow the Wattsons wood teak design too closely. I don’t like the small thin planks in their design especially as it runs down the side decks.

serve.php


And here is the foredeck of a Princess 67 like ours. Here, they have broken away from the Wattsons design but, by keeping the planks straight, they have run into a problem where they have had to add a centre panel where the deck cleats and windlass are located. Again this isn’t what I wanted

serve.php


So, my idea was to follow the Wattsons wood design closer but to take care not to have thin planks in the design. This is how mine ended up.

serve.php


As this thread progresses, I will discuss a DIY concept where I have tried to manufacture and install synthetic teak to the standard that you would expect from professionals. I discussed my intention to post this report with Trakmark who supplied the product that I am using. They are happy that I write this thread explaining the techniques that I have learned so far. Essentially, though, my technique is the same that Trakmark explained when I first started working with their product. There have been areas where I have found some difficulties and as a result I have developed my own techniques which I will explain as this thread develops.

More to follow on the actual making and installing of the upgrade.
 

Hurricane

Well-known member
Joined
11 Nov 2005
Messages
9,393
Location
Sant Carles de la Ràpita
Visit site
Chapter 2
Joining the Material

OK so lets look at the easy bit first – back welding. That means the whole joint is made on the back of the material. With this type of joint, the extruded material is designed to give a perfect finish on to top side whilst being welded underneath.

Trakmark supply their material in a range of colours and plank sizes with the inter plank caulking already moulded into the extrusion. When making a panel you are most likely to use the “double plank” extrusion. Like in this pic.

serve.php


Most of the time, planks are joined by welding a 5mm plastic flexible rod onto the back of each joint. Trakmark’s double plank extrusion forms a “V” groove where two double planks are joined. See in this pic:-

serve.php


To weld two planks together, you heat up the groove that is formed between the planks and at the same time run hot plastic weld rod into the groove. The idea is to melt the plastic so that the planks and the weld rod fuse together without burning through the material.

To do this a hot air welding gun is used. This is mine.

serve.php


Manually, that would be quite difficult to get right for large areas so a “Speed Nozzle” is used on the welding gun. A speed nozzle looks like this:-

serve.php


As you would expect, just holding one piece against another and welding won’t work. Before welding I found that it is crucial to squeeze the two planks together so that they are tight enough together that you can’t see any gap. Also, each plank needs to be clamped down tightly to a flat surface before any welding can take place. To do this Trakmark suggested some tools.

A Good Working Surface
Firstly a large flat white base board. Something like Contiboard. I used a couple of sheets of 18mm MDF and stuck some white Formica to them. The base board needs to be white so that you can see any gaps when you place the two Trakmark planks together. I put my working boards onto some old trestle tables that I have so that everything is at a good working height. I suppose you could do it on the floor but I prefer to stand whilst welding.

Weights
I can’t emphasise just how important is it to have lots of weights available. In their workshop, Trakmark use lots of approx 150mm x approx 10mm x approx 75mm mild steel plates joined together in threes. They use these to hold the material down whilst welding.

These are Trakmark’s weights

serve.php


I chose to make some weights that I could also use when installing the teak onto the boat later. I made mine from some mild steel 40mm x 80mm x square section tube that I cut into 150mm lengths and filled with lead.

These are my weights – I made about 28 of them.

serve.php


The idea is that you put these weights either side of the groove that you are going to weld. But if you did that, you wouldn’t be able to get the welder into the groove to make the weld. The solution is a tool like this:-

serve.php


Trakmark now supply these but I made mine from the same components that they use.

Hot Air Gun
Synthetic teak is quite rigid until you get it hot. All you need is a cheap “paint stripper” type hot air gun. I bought this for about 10 quid from Screwfix.

serve.php


Finally, before I show you how to make the weld, I want to add a little technique that helps me. I also have some 30mm x 4mm x 150mm long mild steel plates that I lay on their side to keep the welded joint tight down to Working Surface.

The following pics show how each joint is assembled before welding.

The Work Table

serve.php


The joint ready for welding

serve.php


In this pic you can see my addition of the small steel plates to keep the joint in place.

serve.php


The Welding Process
Remember, this is how I’ve learned to do the process. There are probably better techniques out there and people who do this every day probably have better methods.

Firstly, I heat the joint using the “pain stripper” heat gun – backwards and forwards a few times.
Then I run a screw driver down the joint to ensure that both surfaces are laying flat on the white surface. I then double check that there are no white bits showing through the joint from below. Then I start the welder, feed some welding rod into the speed nozzle and slowly draw the welder along the joint being careful to make sure that the welder melts the plastic without burning a hole through. You have to push quite hard on the joint with the welder to force the heated weld rod into the joint. Without all the weights holding the joint together the force of the welding process would move the material apart.

Here is a video of the whole process.


In a perfect joint, the weld rod will end up flush with the back surface of the plank. But in the real world, you may have to trim it off to help the joint lay flat when it is the correct way up.

So to finish this post, here is the final result of the weld in the above video.

serve.php


and when turned over it looked like this

serve.php


So thats how the bulk of the joints are made – back welding.

The more complicated jointing (top welding etc) will follow in subsequent posts.

I did most of my welding during the winter in my garage in the UK but we had to finish some of it on site. Done during lock down whilst we were stuck in Spain!!!

In the March sunshine – nobody else in the marina – we had the place to ourselves.

serve.php
 
Last edited:

MystereMarcus

Member
Joined
9 Feb 2010
Messages
253
Visit site
Absolutely stunning job. Like Bruce I'm considering doing the same on my boat. Looking at Trakmark's site, the materials seem to work out about £100 per square metre plus all the tools. How does this compare to a fitted product (I'm guessing easily half the price!).
 

Hurricane

Well-known member
Joined
11 Nov 2005
Messages
9,393
Location
Sant Carles de la Ràpita
Visit site
Absolutely stunning job. Like Bruce I'm considering doing the same on my boat. Looking at Trakmark's site, the materials seem to work out about £100 per square metre plus all the tools. How does this compare to a fitted product (I'm guessing easily half the price!).
Very roughly you will pay around £350 per sq m fitted plus the removal of the old teak.
Maybe more if you want borders.
And about £200 per sq m supply only to your own templates.
Maybe more if you want borders.

Remember it is easy to make if you don't need borders.
Without borders, you can get away with just back welds.

As I say, the more difficult part will come in my following posts.

BTW - nobody has yet mentioned "Snapes".
Snapes will be the subject of my next post.
 

Elessar

Well-known member
Joined
10 Jul 2003
Messages
9,956
Location
River Hamble
Visit site
Brilliant. So enjoying reading this! And I don't doubt the close up quality matches everything else on your absolutely immaculate boat.

When I chose Flexiteek (over 6 years ago now) it was because it was the only one at the time with subtle colour variations in the plastic.

Does trakmark have this feature?
 

Hurricane

Well-known member
Joined
11 Nov 2005
Messages
9,393
Location
Sant Carles de la Ràpita
Visit site
When I chose Flexiteek (over 6 years ago now) it was because it was the only one at the time with subtle colour variations in the plastic.
Does trakmark have this feature?

Not exactly but the Flexiteek I have on the platform has a smooth finish.
The Trakmark that I've fitted to the bow and side decks has more of a wood feel to it.
They both have their own advantages but I think I prefer the Trakmark.
You wouldn't notice it unless it was pointed out but my Felxiteek has gone a bit pinkish.
I believe that the Trakmark's colours are more robust.
 

timbad

Active member
Joined
15 Apr 2005
Messages
585
Location
UK & The Med
Visit site
Hurricane,
After observing you throughout the complete process from research, templating, design, learning the art of making up the product (even making the lead weights ) though to the final instillation you truly have selected a winner with Trakmark. The final confirmation for me was last week watching you wash down the boat with very little time spent on the decks unlike teak for it to look truly fantastic a true credit to Trakmark , you and AH !
A big (y) all round
 

Hurricane

Well-known member
Joined
11 Nov 2005
Messages
9,393
Location
Sant Carles de la Ràpita
Visit site
you and AH !
Oh yes, later on, I was going to mention my yachtie friend who has helped with this project.
I made the decks myself with some help from SWMBO but when it came to installing it my yachtie friend was more than helpful.
It is great to have friends like him.
As you know, he is currently self isolating on his boat somewhere between mainland Spain and Ibiza!!!
 

Hurricane

Well-known member
Joined
11 Nov 2005
Messages
9,393
Location
Sant Carles de la Ràpita
Visit site
oops . lol how many hours doing the teak.
Difficult to say
I spent a long time working out the technique.
There is still lots to learn.
I guess it took me about 3 weeks on and off to make it up
But as you will see in the next chapter - I did the port deck - rolled it up - put it in a bag - and took it on Easyjet to see how well it fitted.
Then brought it home and made the starboard side.
More on that later though.
 

TheCoach

Active member
Joined
10 Oct 2019
Messages
164
Visit site
Great work @Hurricane really interesting to see how you have gone about this and thanks or takingh the time to detail the process! I know from some of my posts on other forums sometiumes it feels like the write up takes longer than the job:rolleyes:

Cheers,
TC
 

Greg2

Well-known member
Joined
24 Jun 2002
Messages
4,292
Visit site
An interesting read.

I completely agree with your views on real teak and having had a boat with it I swore that we would never buy a boat with teak decks again.........but our new (to us) Hardy is covered in the stuff!!

I am thinking that we will replace it with synthetic teak at some point but not sure that I am up to doing a DIY job.
 
Top