You know how one thing leads to another right? Well, from the picture above, you can see that in mid-April, we noticed that the back arbor had rotted and failed so we had to do something immediately. We propped it up, temporarily, while we did a ton of research on what to replace it with.
Several times I was able to get help from friends and neighbors. Here’s Derek (neighbor), Bill and John along with reliably helpful Alex as we tore off the decking to save it for later. Note the discoloration on the floor joists.
I took my time
Virtually every day, I started with a cup of coffee and often had another cup of coffee during the day while I contemplated what my next move would be. Some days I was able to work 7 or 8 hours but most days I worked half days with lots of computer research or planning (sometimes napping). Lynda was very patient and supportive with me. She was very responsive to all my questions and helped when it wasn’t too heavy.
Most of the nails were so corroded that they came out as we pulled the Trex. In many cases, the nails broke off.
As we tore down the attached pergola, we saw that the supporting structure under the old Trex was questionable. It was attached with steel nails which corrode against pressure treated lumber. We had to remove and reinforce most of joists and completely rebuild the far end as there was earth to wood contact and it had sunk into the dirt. We didn’t want to replace the whole top of the deck, so we removed and saved the old Trex (which was nailed on!) and repaired/rebuilt the supporting structure.
We had to dig out a couple of wheelbarrows of dirt
However, there was a deadline. We had to have the deck back in place in time for Alex’s Graduation ceremony. Fortunately, we were able to get that done in time.
With help we finished the top of the deck in time for the graduation. (You can click on some images to enlarge)
We considered a few different options for the ceiling joists and the steps and finally went with the similar dimensions as previously. The angles were tricky and needed a full-size drawing to ensure all the parts fit together properly. Took over the whole table for a few weeks to stage the various portions of the design. I manufactured the straps from 1/8 steel straps I bought at Home Depot. The PVC coverings took some time to arrive which gave me tons of time to finish the deck.
Finally got the ceiling joists installed
Installed posts in post holes surrounded by cement and, with help from Alex, got the headers installed too. Then John came and we installed the ceiling joists. While there were tons of details, it was fun taking my time to do things as best I as was able.
Meanwhile, Lynda found the perfect outdoor sectional for the corner. Both Ray and Alex tested it out to make sure it would be comfortable for our guests.
Eventually, by Thanksgiving, many of the little details were finished — good enough! Still a few little things but is anything ever really “finished”? (You might have to zoom the image above to see the wires between the posts in the railing.)
Actually, there’s a ramp on the far side. It has the posts for a railing, but they need painting and, also, I need to install the wires and a railing.
Here’s what this side looks like now. Maybe by next Christmas, I’ll have it finished!!
Top is a close up of the joint. The bottom is looking towards the kitchen door. That picture was taken earlier as you can see from the 4×4 posts that I hadn’t trimmed yet.