How to Make Pontoon Boat Railings

You can construct an attractive and sturdy railing for your pontoon boat using components available through brick-and-mortar or online marine hardware stores. The railing system is anchored with tubing bases that are bolted to the deck. These are reinforced with metal or plywood backup blocks. Tubing is cut to make 33-inch stanchions, which are placed into tubing bases for upright support. Elbows and T-shaped connectors, called universal tees, fit over the stanchions and hold tubing for hand rails. The railing is secured with Allen screws.

Things You'll Need

  • Measuring tape
  • Tubing, stainless or bright anodized aluminum
  • Rail bases with Allen screws, stainless steel or chrome zamak, round or rectangular
  • 90-degree elbows with Allen screws, stainless steel or chrome zamak
  • Universal tee with allen screws, stainless steel or chrome zamak
  • Mill finish aluminum sheet or 3/4-inch marine plywood, 12 inches by 18 inches and 25 gauge thickness
  • Pencil or marker
  • Vise or clamp
  • Jigsaw with metal or plywood blade
  • Railing base bolts, nuts and washers
  • Electric hand drill and drill bits
  • Marine adhesive sealant
  • Hacksaw
  • Rags or old towels
  • Screwdriver and wrench to fit bolts
  • Acetone
  • Metal file
  • Allen wrenches
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Instructions

  1. Project Planning

    • 1

      Use a measuring tape to measure the beam and length of your pontoon boat's deck and multiply by two. Round up to the nearest foot. This will be the total amount of tubing you will need for the hand rail.

      Decide where to locate your gates, if any, and the upright tubing supports for the railing. Do not space the upright tubing more than 13 feet apart. Plan for supports on both sides of gates and in the corners.

    • 2

      Multiply the total number of vertical supports by 33 and divide the total by 12. This will be the total feet of tubing you need for stanchions for vertical railing support.

    • 3

      Add the total number of feet of tubing you calculated for the railing in Step 1 to the total amount of tubing you calculated for vertical supports. This is the total number of feet of tubing you need to make the pontoon railing.

    • 4

      Determine how many lengths of tubing you will need to purchase. Tubing comes in lengths of 6, 12 and 20 feet.

    • 5

      Determine the number of 90-degree elbows that you need. Count one for each corner and two for each gate.

    • 6

      Determine the number of universal tees that you need. Count one for each vertical support that is not a corner or gate support.

    Install the Rail Bases

    • 7

      Place the rail base on the aluminum plate or 3/4-inch marine plywood. Outline the rail base by tracing around it with your pencil or marker. Mark spots for drill holes. Repeat for the other rail bases.

    • 8

      Secure the aluminum or plywood sheet with a vise or clamp. Use the jigsaw with the metal or plywood blade to cut out each outline. These are the rail base backup blocks.

    • 9

      Position the rail base on the deck where it is to be installed. Use the pencil or marker to mark the bolt hole locations on the deck.

    • 10

      Use the electric hand drill and bit to drill holes through the marked deck and the marked tubing base backup block. Use a bit size slightly larger than the diameter of the bolt.

    • 11

      Apply marine adhesive sealant to the underside of the rail base and the top side of the rail base backup block. Insert the bolts through the holes in the rail base, through the deck, and through the holes in the rail base backup block. Slip on the washers and attach the nuts. Use a screwdriver and wrench to tighten the nuts and bolts. Clean up excess sealant with acetone and a rag.

    • 12

      Repeat this process for the other rail bases.

    Make and Install the Stanchions

    • 13

      Wrap the tubing with a rag or old towel and use the clamp or vise to secure it. Take care not to bend or scratch the tube.

    • 14

      Use the jig saw with the metal cutting blade or the hack saw to cut the tubing into 33-inch lengths. These are the stanchions.

    • 15

      Use the file to clear away any metal shavings or ragged edges at the cut.

    • 16

      Loosen the rail base Allen screws to permit the stanchions to seat fully. Insert all of the stanchions into the rail bases. Gently tighten the Allen screws, leaving some play.

    Install the Elbows and Universal Tees

    • 17

      Use the file to remove any metal shavings or ragged edges from the top of the stanchions.

    • 18

      Loosen the Allen screws on the 90-degree elbows to permit the stanchions to seat fully.

    • 19

      Place the 90-degree elbows over the stanchions and push down into place.

    • 20

      Gently tighten the Allen screws, leaving some play.

    • 21

      Repeat this process to install universal tees on the remaining stanchions.

    Make and Install the Hand Rails

    • 22

      Wrap the tubing with a rag or old towel and use the clamp or vise to secure it. Take care not to bend or scratch the tube.

    • 23

      Use the jigsaw with the metal cutting blade or the hacksaw to cut the remaining tubing in lengths that extend from a corner's 90-degree elbow to the next 90-degree elbow.

    • 24

      Use the file to remove any metal shavings or ragged edges from the cuts on the hand rails.

    • 25

      Loosen the Allen screws on the 90-degree elbows to allow the tubing to enter freely. Slide the tubing for the hand rails into place. Gently tighten the Allen screws as you work.

    • 26

      Use the Allen wrench to tighten all the Allen screws when all the hand rails are in place.