I'd just remove the teak and go with a glass deck
and non skid.
If you want the teak deck
, what you propose is doable but very labor intensive. Just cleaning
the old caulk off the wood and the deck could take weeks. Filling the screw pukas is the fast part. Relaying the teak and gluing it down will probably be the easiest job since the wood is already prebent to shape. I can just see the hours and dollars adding up and up to do the project
As far as thickness of the relaid teak, it probably would be still be thicker than most new boat's glued teak deck. One of the reasons they've gone to glued teak decks is they can use much thinner teak. Just recently saw repair on an Aussie or NZ built boat with glued teak decks. The teak planking was only about a 1/4" thick and started coming apart after a decade or two because the wood was so thin. On that boat, the owner replaced the teak deck. They used a company out of somewhere on the US West Coast
that prefabbed the wood already cut to fit and shipped it to Hawaii
. Think they flew someone out from the supplier to do the design and measuring. The new deck was 1/2" thick and looked like it would go together very nicely. The carpenter
who did the work was very experienced and very good which helped a good deal I'm sure. I saw the kit laid out on the shop floor before it was installed and it looked like it was well done. Haven't talked with the carpenter
to see how the actual install went, however. One thing, bet it wasn't cheap
. The boat sat in the yard for well over a month, maybe two, with tearing off the old deck, measuring, fabricating and shipping
the new deck, and the installation
so lay days in the yard alone were into the thousands. Airfare and hotel
for the guy who did the measuring would be at least a boat unit unless he combined it with a vacation
in the islands.