How to Rebuild a Pontoon Boat

With the inherently stable, twin-hull, small-water-plane area vessel called a pontoon boat, a rebuild follows a set pattern. While no two pontoon boats are exactly alike, when you start to rebuild them, the first efforts should make your boat watertight and seaworthy. After those two critical needs are met, you can relax a bit and let your imagination run free as you dress out the boat’s interior. The process begins after you have a professional marine surveyor’s inspection report in hand so you learn what problems lurk within. Then, you can begin one of the most challenging projects a boater will face.

Things You'll Need

  • Surveyor's report
  • Wide plastic wrap
  • Duct tape
  • Gel coat paste
  • Narrow plastic putty knife
  • Marine epoxy
  • 1 1/2 ounce fiberglass mat
  • Fiberglass roller
  • 6-ounce fiberglass cloth
  • Automotive paste wax
  • Marine plywood
  • 220-grit sandpaper
  • Orbital sander
  • 400-grit sandpaper
  • Paint
  • Through-hull fittings
  • Reciprocating saw
  • Wide metal putty knife
  • Steering wheel
  • Helm
  • Steering cables
  • Seals
  • Hatch gaskets
  • Fire extinguishers
  • Life vests
  • Surveyor's report
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Instructions

    • 1

      Stretch wide, clear plastic wrap across small holes in the hull and secure the wrap in place using duct tape. Mix gel coat paste according the manufacturer’s directions and apply to the plastic from inside the hull, using a narrow plastic putty knife.

    • 2

      Mix marine epoxy according to the manufacturer’s instructions. Lay a sheet of 1-1/2 ounce fiberglass mat over the gel coat and apply the marine epoxy to the mat, working the epoxy into the mat with a fiberglass roller. Lay a sheet of 6-ounce fiberglass cloth. Apply epoxy. Continue to add alternating layers of fiberglass and epoxy until the hull patch is the thickness of the skin of the hull.

    • 3

      Allow the fiberglass to cure fully. Remove the plastic wrap after 24 hours. Wax with good quality automotive paste wax.

    • 4

      Patch large holes in the hull with marine plywood. Lay alternating fiberglass mat and epoxy over the plywood, finishing with epoxy. Sand the epoxy flat with 220-grit sandpaper and an orbital sander. Sand the surface to a gloss with 400-grit sandpaper, clean the sawdust away and allow the fiberglass to cure. Paint and wax the repair.

    • 5

      Replace any damaged through-hull fittings based on the report of their condition in the marine surveyor’s report.

    • 6

      Beginning at the bow – the front of the boat – use the notes on the marine survey to locate soft decking. Cut the hull away with a reciprocating saw and replace the stringers – the hull’s longitudinal structural members -- beneath the deck. Replace the deck, using marine plywood. .

    • 7

      Apply marine epoxy to the surface of the plywood, using a wide metal putty knife. Sand the surface flat, using an orbital sander and 220-grit sandpaper. Finish the surface to a high gloss with 400-grit sandpaper, and wax with automotive paste wax

    • 8

      Replace the steering wheel, helm, steering cables and associated hardware, if necessary. Replace any seals and hatch gaskets.

    • 9

      Replace the cockpit and interior appointments according to your taste. Replace the safety appliances, such as fire extinguishers and life vests.

    • 10

      Order a new survey of the vessel, if desired. Make any additional repairs noted in the new survey.