Mini Pontoon Build Along

[SHaugh]

As Discussed in this Kayak thread:

 

http://www.bassresource.com/bass-fishing-forums/topic/145620-kayak-fishing/page-3

 

I will post various instructions on how to make my mini pontoon boat:

 

 

 

 

 

I will keep my instructions fairly brief.  But if you have questions go ahead and ask.  

 

The first step is to build the pontoon outer covers.  For that you will need to purchase 4 (edited, I forgot the carpet for the decking)  of these carpets from Home Depot:

http://www.homedepot.com/s/foss%2520area%2520rug?NCNI-5

 

I suggest the one called Ribbed Chocolate.  The ribbed texture looks best to me, and the brownish color hides water discoloration best.

 

 This diagram shows the cuts sizes.  For this boat I will assume that you will purchase solid polystyrene cylinders, so disregard any discussion of Mesh bags.  

 

[SHaugh]

Cut the carpet into the sizes shown.   you will have room for the circles on the ends of each large cut piece.  The third carpet is simply cut in half to make the 2 wraps that will secure the pontoons to the boat....  see the picture...  the 4th carpet is for the deck.

[OroBass]

Were do you buy the styrofoam

[SHaugh]

There are lots of places to buy it. 

 

I use these guys... 

http://www.drewfoam.com/

 

They will sell a 21" diameter x 18" diameter block for about $22.    You need 4 per pontoon....  Shipping cost is pretty high on that stuff ... so you should try to find somebody local where you can pick it up....

 

this is another online guy... prices are higher though...

http://univfoam.com/

 

 

you can buy this stuff from Home Depot.. and cut it up into circles:

http://www.google.com/shopping/product/1?lsf=seller:8740,store:3128122207190988578&prds=pid:984924210147033064,oid:984924210147033064&hl=en&cm_mmc=shopping-_-googleads-_-pla-_-202090244&ci_sku=202090244&ci_gpa=pla&ci_src=17588969&gclid=CNzT4pnxu8ECFUgA7AodeFkAqA

 

If you do this you can use the leftovers to make spacers like this.  21" diameter circles and 6" tall partial circles.  stack them all up into about 18" high stacks.. use a little super 77 spray glue to hold them together.   You will need 9 sheets per pontoon.

[J Francho]

You're already pretty close to $250 in materials, not including the platform, transom,  any tools, and sewing machine accessories (assuming you have one that can handle the carpet.)

 

This is what I'd consider about the cost of a better than entry level kick boat.  Don't get me wrong, it's cool, and it's not going to sink if punctured.  I bet it's heavy when soaking wet, too.  Seems overly complicated for the typical person.

[SHaugh]

If you want cheap you can fill them with empty water bottles or scrap EPS foam, I think most people would want to do it a little better...

 

My cost estimate for the boat would be around $390 with the solid polystyrene pontoons.

 

IF cost is an issue you can also use some solid polystyrene blocks and fill the gaps with scrap or empty bottles.

 

Whatever you do the amount of buoyancy will be way more than adequate.

[SHaugh]

You're already pretty close to $250 in materials, not including the platform, transom,  any tools, and sewing machine accessories (assuming you have one that can handle the carpet.)

 

This is what I'd consider about the cost of a better than entry level kick boat.  Don't get me wrong, it's cool, and it's not going to sink if punctured.  I bet it's heavy when soaking wet, too.  Seems overly complicated for the typical person.

It's not heavy when wet... that carpet doesn't hold much water.... it runs right out.  it weighs about 45 lbs dry.. .about 50 pounds fresh out of the water.  Easy to throw into a pickup.... even wet...

 

A Kayak is not for everybody... this gives you a very high platform that let's you use a comfortable chair...  the canopy is also included in that cost... a nice feature down south in the summer...

 

A lot of people like the DIY nature of it... they can make it exactly how they want....  I agree it's not for everybody....    If you want easy buy a plastic bass raider..

[J Francho]

I didn't mention a kayak, was talking about pontoons/kickboats.

[SHaugh]

I thought a kickboat was a foot powered kayak... I'd never seen those before... but again the comfort aspects are in favor of my boat.  You are sitting only inches above open water ... much different than the comfort level of this boat.  I have an old office chair I modified to use on mine..  super comfortable.. super stable...  Kick boats look like swimming to me...

 

Here's another example of a boat I made...  Way more boat for $300 than a kickboat or air filled pontoon... IMO...

 

[SHaugh]

Since cost seems to be a concern I will outline a generous estimate:

 

Carpet    $76

Polystyrene  $170  (Or $0  depending how much you want to spend)

Decking  $25

Wood $15

railing $60 ( this is optional.. you can spend less)

Motor mount  $10

Hardware/ misc $10

Sewing labor...$20  (If you need somebody to sew your pontoon covers)

 

Total cost $386 for the solid polystyrene model.

 

For a version in which you will scrounge your flotation from "free" materials  $216.

[J Francho]

Looks really good, man.

[Crappiebasser]

I have them made from 30 plastic drums but never carpet. Seems like the water weight in the carpet would cause a lot of drag.

[SHaugh]

The carpet behaves very well in the water... it doesn't get "very" wet... it has only a very light backing... you will need to see it to understand.  It behave just like a mesh... water passes right though it...

 

The drag of the carpet and flat front ends is also of minimal concern...  since you are only going a couple mph with a 30 lb motor it's not an issue at all..

 

This boat is not for a gas engine...  it's also not for big rough water...    it works perfectly on small lakes with small waves.   Just like the other similar products on the market.

 

The weight of the water momentarily trapped inside the pontoons has another benefit.  It makes the boat almost impossible to flip over... It's very stable....  

[SHaugh]

Here is how I built the decking on the super light version.   I won't go into detail how to use Tnuts and bolts to complete this construction.  But if you need help just ask me.

 

Plywood for the deck is usually a point of discussion.  Some people insist you need Marine grade plywood.  but that is too expensive for me... and hard to get in TN.  I just buy good quality hardwood plywood and coat it with several thick layers of polyurethane varnish.  Especially on the edges... I also use a Q tip after I drill all the holes and coat those inside edges really well.  Do that and any plywood will last for years.   Don't use the cheap 1/2".. get birch plywood,  it's lighter and stiffer.   If you are not worried as much about weight  because you will use a trailer just buy 3/4" ply.  Use the polyurethane on all wood parts... then paint.... will last for decades ....

 

[Jay Ell Gee]

Ill tell you what, it's the most comfortable looking DIY build I have seen. Any plans to include cup holders for a cold beverage? That looks like the only thing it needs!

[SHaugh]

yup... it pivots off the railing.  Locks down with an eyebolt..  I just cut down one of the canopy fittings to get the locking sleeve... a good place to set your baits... and brew..

 

[hoosierbass07]

I'd fish from it! How much weight does it hold?

[SHaugh]

^{I weigh 240... with battery and a heavy chair it's nowhere near capacity...  My guess would be you'd need to worry if you were over 300... with solid polystyrene floats  probably 400 lbs...}

[SHaugh]

When you have your plywood and footpads for the railings lay out all your holes and drill...  holes should be 5/16" all around.

[SHaugh]

Once you have your boards cut and drilled use a small roller and cover everything with a couple thick coats of polyurethane varnish.. pay special attention to the edges and use a Q tip to do inside all the holes.  Let it dry for a day.

 

Next pound in your T-nuts.    They will all go into the deck plywood.  Note in the drawing above.. some go on the top.. some on the bottom..

 

Once you have all your wood varnished and the T nuts in give it a good coat of paint.   I just use latex house paint.. but you can use oil based if you like.

 

 

Test fit all your pieces once more to be sure you got it right.   Next step is to carpet the deck.

 

Scratch a little outdoor carpet glue on the top surface:

 

 

Then line up your piece of carpet... make the ribs run front to back.  check to be sure it's nice and straight.. otherwise it will look bad with carpet lines running at an angle...

 

Next using a staple gun..  ( a hand powered gun will work fine) ...  staple the carpet with about a 3" wrap on the bottom:

 

Notch out where your T-nuts are.

[SHaugh]

On the top surface use an old soldering iron to melt a hole in the carpet for the footpads.

 

[WillJ]

I don"t know if I'd like casting frequently off this, but it'd be relaxing to bait fish off of for sure. On a contraption such as this a cold brew is only necessary. This is cool though. 

[buzzed bait]

more engineering than my brain is capable of!!

only question i have is how do you transport it and how much time does it take to set it up at the ramp?

[SHaugh]

I don"t know if I'd like casting frequently off this, but it'd be relaxing to bait fish off of for sure. On a contraption such as this a cold brew is only necessary. This is cool though. 

The way I made the canopy you have more than 180 degrees in front of you... If you need to cast straight overhead just leave the canopy off that day.... unscrews by hand with a couple eye bolts.

[SHaugh]

more engineering than my brain is capable of!!

only question i have is how do you transport it and how much time does it take to set it up at the ramp?

Fits in the back of my short bed pickup perfectly with the gate closed..only takes a minute or 2.... back down the ramp, pull it off.... put the canopy on.. attach the motor.. grab the chair battery and gear....  less time than launching a trailered boat...