Replace Plywood Section on Deck

Tools:

straightedge
hammer
pry bar
utility knife
calipers
push drill
caulking gun
spring clamps
paint brush
paint roller
paint tray
power drill
circular saw
broom
scrap lumber
wood blocks
square
towel
dust mask
safety glasses
elastimeric textured coating
caulk
screws
primer
5/8-inch plywood

Steps:

1. Locate the seam lines around edge of damage plywood piece. Line the straightedge up with the seams and make a cut through the anti-skid coating using a utility knife.

2. Use a square to mark the corners around the nail heads, then extend the lines using the straightedge to the next seam.

4. Line up and temporarily attach a piece of wood to the deck to work as a guide for the circular saw.

5. Use calipers to measure the thickness of the plywood (figure B). Set the depth of the circular saw to that depth. Be careful, go too deep and you may cut the joist.

6. Put on safety glasses and dust mask. Use a plunge-cut to lower the saw into the wood and make the cut (figure C). Do not cut beyond the boundary of the square.

7. Inspect the edge of the adjacent piece, making sure there's no water damage or rot. Make a series of small cuts in order to remove the damaged section of wood a little bit at a time.

9. Line up and attach a piece of wood to the new piece of plywood to act as a guide for the circular saw and cut plywood to fit.

10. Draw a line above the center joist as a marker for driving in screws.

12. Clean up debris left and caulk around the edge of the new piece, sealing the edges against the weather (figure F). Smooth caulk bead with a finger.

13. Caulk along the edge of the new seam, and then smooth the bead with a finger.

14. Paint on a coat of primer, then apply textured coating with a roller (figure G). Allow the coating to dry for 24 hours, then roll on a second coat.