The deck is the last to be used so it is the first plank I will assemble.  It's also the most difficult just because it is the largest joint of all.  I did several test fittings and dry runs to make sure things would go well.


These joints are a bit different than anything I have done before.  They are precision cut with asymetric gaps to facilitate bonding with gap filling epoxy glue.  Some parts of this joint touch and some parts have gaps almost 1/16 inch wide.  The result is a joint that perfectly aligns the components and provides a strong joint in our extremely thin 4 mm plywood.

I want the joint to be clean without the need for extensive sanding and post bonding cleanup so I will use clear packing tape to mask off the joint.


This is the final dry run of the temporary jig.  Although the joint will align everything, I need to control exactly how things go together so it is repeatable.  This doesn't matter so much with the deck, but for the other planks I want everything identicle on each side. 


I have applied the tape to one side of one joint.


And then trimmed it flush with a razerblade.  This is sort of time consumming, but worth the effort (I hope) because cleanup should be minimal.


I saturated each joint with unthickened epoxy.  That step took 2+2 (resin + slow hardner) of unthickened epoxy for BOTH joints.

Then I added epoxy thickened with wood flour (West 205) and a medium density microfiber (West 203).  That step took 2+2 for EACH joint.  That was way more than I expected and I didn't have much left over.  These joints provide a lot of surface area for the bond.

Now I just have to wait till the next day for this deck to be ready for the pile.