Wednesday, June 24, 2020

Deck Building Process

The lumber and the decking are here; no more waiting and wondering. I've spent $4,400 so far, including the kitchen shelving and a few miscellaneous things. 46.67% of the money went to Fiberon decking, not to mention $337 for hidden deck fasteners. But that's less than Home Depot offers online (and I have it now, not mid-July).

What order shall we do things?

In general, I think I should build the framing and stain it black before installing any Fiberon. But I can finish the upper deck before starting on the lower. I'll apply lessons from one to the other.

The Fiberon installation manual recommends against the flat 2x4 blocking I was thinking about to support the "picture frame." They say it can trap water, and I was planning to use composite fascia then, anyway. I need to get my design straight.

  1. Design the upper deck "picture frame" blocking and post attachment. Make a decision about any further Simpson connectors.
  2. Cut the 2 2x4 intermediate posts and attach them temporarily. Treat cut ends.
  3. Use an old deck board to create a cable rail template.
  4. Remove 6 posts and drill 1-1/4" countersink, then 1/2" through. Re-attach them plumb in both directions and keep them plumb with temp braces.
  5. Cut and install the 5 pieces of 2x4 sub-rail. Treat cut ends.
  6. Cut and install the new 2x8 blocking.
  7. Buy a table saw (or borrow Kevin's?). Buy a 4" drill bit slightly bigger than 1/8" cable.
  8. Rake the dirt, establish finish grade. Install the weed fabric.
  9. Cut and install 2x4 "X" bracing under the joists. Treat cut ends (or skip it).
  10. Use the cable rail template to drill 8 holes through 8 posts.
  11. Connect the 8 posts for real; remove the temp braces
  12. Black stain visible parts of the frame, along with the "vault" hatch
  13. Install the acrylic tape flashing after the stain
  14. Install the composite picture frame using TrapEase screws and solid edge boards. Stay 1/4" from the house at BR2
  15. Layout 5.5" centers 1/4" from the house at the breezeway. Start at the top of the steps and work back toward the house. Rip the Fiberon board at the house using the table saw. Fill in the triangular extension pieces, cutting angles as necessary.
  16. Layout 5 stringers; verify height to concrete. Design stringers on paper if necessary, then carefully transfer to a 2x12. 
  17. Cut one 2x12 and test fit against the deck. If it fits, clone it 4 times.
  18. Attach 5 stringers to the rim joist/girder and cut a 2x4 to align the toe. 
  19. Black stain the stringers and 2x4.
  20. Apply butyl tape to the runs.
  21. Cut (miter) 4 tread picture frames and install them.
  22. Cut and install the rest of the treads;
Then, move on to the lower deck.

  1. Main Girder
    1. Cut 2x8x8' in half, then create main 15' 6" girder. 
    2. Establish top of girder at 8-1/4" below the finished deck by marking concrete foundation wall. Use temporary braces to float girder at that level.
    3. Dig and set the piers on undisturbed soil under the girder. Cut 4x4 scraps to fit from girder to pier. Install them and remove the temporary braces.
  2. Secondary Girder
    1. Create the 11'6" (verify dimension) girder from 2x8x12'. Install temporary "joists" and mark 6' on them. Prop the girder on temporary braces so that it is level and aligned with the first girder.
    2. Dig and set the piers on undisturbed soil under the girder. Cut 4x4 scraps to fit from girder to pier. Install them and remove the temporary braces.
  3. Stair Girder
    1. Create 4'+ (verify dimension) girder. Move the temporary "joists" to the west end and mark 3'4" on them. Prop the girder on temporary braces so that it is level and aligned with the first girder.
    2. Dig and set the piers on undisturbed soil under the girder. Cut 4x4 scraps to fit from girder to pier. Install them and remove the temporary braces.
  4. Cut and install joists 1, 4(dbl), and 10. Cut and install rim joist at the prow, joist 13, at the stairs.
  5. Cut and install joists 2, 3, 5, 6, 7, 8, 9, 11, 12.
  6. Rake to "finish grade" and install weed fabric.
  7. Install solid blocking along the main and secondary girders (stair girder uses rim joist). Install "ladder" blocking at east and west ends
  8. Cut and install 10 4x4 posts and 3 intermediate 2x4 posts. Drill 1-1/4" countersink, then 1/2" through. Plumb them and hold with temporary braces.
  9. Cut and install the 8 pieces of 2x4 sub-rail. Treat cut ends.
  10. Buy a table saw (or borrow Kevin's?). Buy a 4" drill bit slightly bigger than 1/8" cable.
  11. Cut and install 2x4 "X" bracing under the joists. Treat cut ends (or skip it).
  12. Use the cable rail template to drill 8 holes through 10 posts.
  13. Connect the 10 posts for real; remove the temp braces
  14. Black stain visible parts of the frame
  15. Install the acrylic tape flashing after the stain
  16. Install the composite picture frame using TrapEase screws and solid edge boards. Stay 1/4" from the house
  17. Layout 5.5" centers 1/4" from the house at BR3. Start at the top of the steps and work back toward the house. Rip the Fiberon board at the house using the table saw. Fill in the triangular extension pieces, cutting angles as necessary.
  18. Layout 5 stringers; verify height to concrete. Design stringers on paper if necessary, then carefully transfer to a 2x12. 
  19. Cut one 2x12 and test fit against the deck. If it fits, clone it 4 times.
  20. Attach 5 stringers to the rim joist/girder and cut a 2x4 to align the toe. Cut and install the 11th post against the west-most stringer.
  21. Black stain the stringers and 2x4.
  22. Apply acrylic tape to the runs.
  23. Cut (miter) 4 tread picture frames and install them.
  24. Cut and install the rest of the treads;

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