How to sand deck with nails sticking out?

[bodega]

Hi - restoring an old deck that was built by previous owner. The foundations are pretty good but long overdue to be re-sanded and re-finished as I'm already replacing old boards here and there.

Deck area is roughly 6m x 4m, manageable but still decent work.

Questions:

1) Been putting this off as I noticed all the boards have been nailed in, I've attached some details photos. Will these be ok to sand over? Some of the boards I've had to replace I've used weather proof decking screws which are much better and flush with the deck instead of slightly raised.

2) I was going to buy a belt sander. Or should I hire an orbital sander? I've watched so many tutorial videos but could use suggestions.

All suggestions welcome.

[EricL]

Hi @bodega 

I can only suggest trying to countersink the nails first to see if they go down any further. It will save you a lot of heartache and sandpaper if the surface is nice and flat.

Eric

[bodega]

Thanks @EricL - can confirm this is Merbau decking wood, I'm really not sure if the nails will go down further but I'll try with a new set of nail punches.

If they don't go below the surface, what other options do I have? 

[EricL]

Hi @bodega 

You might need to get a bit creative and use a heavy-duty punch or something similar so that you can drive the head at least to its original level. A heavier hammer perhaps to drive the nail into the hardwood frame?

Eric

[Nailbag]

Hi @bodega 

Go the orbital as I think it will be less aggressive and leave a smoother finish as your boards don't look that bad.. As far as being more forgiving with nail heads, your nails should be well punched in anyway.

I'm doing a lot of deck re-oiling at the moment and I'm wondering if yours needs sanding at all? Though it might be a waste of time and money, but it might also save that and more by using this deck Ultra-prep product and a pressure washer. If you follow the directions it can make an amazing difference in removing a top layer of the flaky surface and bring the wood grain backup. I would still knock the nail heads down but just with your hammer.

Check out the photos below. This deck looks like it was in the same condition yours is in now.

Nailbag

[Dave-1]

Morning @bodega 

One of the reasons I went with a small belt sander was so I could work between the screwheads as there was no way I could make them move (deeper or remove them totally) It was fiddly and not the best way but I would have run up against the screw heads destroying the sanding belt all the time.

Dave

[bodega]

Hi @EricL @Nailbag @Dave-1 

Quick update on my end.

Managed to punch the nails down, ended up getting a heavy duty 5mm nail punch which did the trick, was not easy though but we got there.

Next up, sanding. Still deciding if I use belt sander or hire an orbital or belt sander. 

First question - what grit sandpaper should I be using?

Thanks again!

[EricL]

Hello @bodega 

Thank you for sharing that update. It's good to hear that you managed to sink the nail heads down into the decking panels. I still suggest using the For Hire: Orbital Floor Sander - 24hr as recommended in my post. I propose starting with a 40grit sandpaper and working up to 60grit and finishing with a 160grit or higher for a smooth finish. 

Eric

[bodega]

Thanks @EricL - any idea how much sandpaper I might go through? Should I purchase extra when hiring the sander?

[Nailbag]

Hi @bodega 

Personally I would start with a finer grit only to get the feel for how aggressive it might be especially when using an industrial sander. I would start with 80+ grit. You can always move down.

It's not possible to know how many belts you will go through. I would expect possibly two for the lower grits and one for the finer.

Nailbag

[bodega]

Thanks @Nailbag - good idea on starting with a finer grit. Thanks for that