Overview
The boards on our wood deck had deteriorated with age, so we repaired and replaced them using “cafe boards” (カフェ板, pre-cut planks commonly sold in Japan for DIY tabletops and shelves).
We had done a temporary fix before, but this time we decided to replace a wide area, including some preventive replacement.
Condition Before the Work
Because of moisture and the relative softness of the original boards, some sections of the deck had become loose or were crumbling.
Steps
1. Removing the Old Boards
We used an impact driver to remove the screws from the old top boards and pried the boards off.
2. Preparing the New Boards
For the new top boards, we used cafe boards.
Since we were not covering the entire deck, we trimmed both edges and cut the boards down to a width of 180 mm.
Features of cafe boards:
- Standardized sizes make them easy to work with
- Reasonably priced
- Usually made of Japanese cedar (sugi)
- Somewhat less durable outdoors, but the low price makes up for it
3. Preservative Treatment
We applied two coats of an oil-based wood preservative.
- Drying time: about 3 hours
- Fully dry: 24 hours
Looking at the old top boards we removed, you can see that the damage had progressed from the parts in contact with the joists and from the ends.
4. Installing the New Boards
Here is the deck after the boards were replaced.
The boards look glossy black because the photo was taken right after the second coat of preservative.
Points to watch out for: The hardness of the wood varies from board to board, so screws can sometimes be driven in too deep.
The offcuts will be reused as kindling for the wood stove.
A Break After the Work
On the way home, we stopped at the Starbucks near the Zushi-Hayama Shindo road (逗葉新道) and bought a Halloween-themed açaí Frappuccino. Because it was a takeaway order, it didn’t come with the decorative cat-ear chocolates.
A new shop billing itself as “the world’s smallest chocolate factory” had opened at the parking area along the Zushi-Hayama Shindo.
Prices were generally on the high side, but the milkshake (¥150) was delicious.
We bought about ¥2,500 worth of chocolate.
Summary
We replaced the wood deck boards using cafe boards. Cafe boards are affordable and easy to work with, making them a good material for DIY wood deck repairs. With regular maintenance, a deck can be used for many years.
