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  • Pontoon Boat Repair Questions.

    Got a job repairing a pontoon boat. It's coming Monday.

    I've repaired and modded a few pontoons but this time I will be cutting out bad/crushed sections of the pontoons and welding new sections in.

    I plan to plasma cut the bad out and have 1/8" aluminum patch panels rolled to a 24" dia at a sheet metal shop, and then weld them in.

    Probably try the spool gun first but have a tig.

    I know some people on here have talked about repairing pontoons before, I just wanted to see if there is anything special I should look out for.

    (I know the inside is going to be a scummy mess.)

    Thanks,

    James

  • #2
    I have seen a few with foam sprayed inside the tubes...Bob
    Bob Wright

    Spool Gun conversion. How To Do It. Below.
    http://www.millerwelds.com/resources...php?albumid=48

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    • #3
      Originally posted by jamscal View Post
      Got a job repairing a pontoon boat. It's coming Monday.

      I've repaired and modded a few pontoons but this time I will be cutting out bad/crushed sections of the pontoons and welding new sections in.

      I plan to plasma cut the bad out and have 1/8" aluminum patch panels rolled to a 24" dia at a sheet metal shop, and then weld them in.

      Probably try the spool gun first but have a tig.

      I know some people on here have talked about repairing pontoons before, I just wanted to see if there is anything special I should look out for.

      (I know the inside is going to be a scummy mess.)

      Thanks,

      James
      I have fixed several hundred myself over the last dozen years.(seriously) What brand and year model is the boat?? I may be able to offer some help.
      Many companies sell more here than any other lake.

      www.facebook.com/outbackaluminumwelding
      Miller Dynasty 700...OH YEA BABY!!
      MM 350P...PULSE SPRAYIN' MONSTER
      Miller Dynasty 280 with AC independent expansion card
      Miller Dynasty 200 DX "Blue Lightning"

      Miller Bobcat 225 NT (what I began my present Biz with!)
      Miller 30-A Spoolgun
      Miller WC-115-A
      Miller Spectrum 300
      Miller 225 Thunderbolt (my first machine bought new 1980)
      Miller Digital Elite Titanium 9400

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      • #4
        Foam inside the tubes will definitely suck. I hope that's not the case.

        Don't know the model or year off-hand, but it's a 28' long with 24" diameter pontoons.

        I'll try to take pics of the repair.

        -James

        Comment


        • #5
          All depends how old the boat is and how much it was in the water, expecially salt water. You may be wasting your time. The tubes may be worn down to the point that you can't find a good spot to weld too. I was going to have mine welded on my 84 pontoon but this was the case, ended up trashing it and buying another.
          Ken

          What else is there besides welding and riding. Besides that

          Miller Thunderbolt XL 300/200 AC/DC
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          Dewalt Chop Saw
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          2009 FXDC

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          • #6
            If the tubes are round it will probably be chambered rather than foam filled.
            U-shaped tubes have the foam in them generally.
            Try pdbworld.com for more info...there is an awsum pontoon forum there. I was the second member to join it and it has grown a bunch since then.

            www.facebook.com/outbackaluminumwelding
            Miller Dynasty 700...OH YEA BABY!!
            MM 350P...PULSE SPRAYIN' MONSTER
            Miller Dynasty 280 with AC independent expansion card
            Miller Dynasty 200 DX "Blue Lightning"

            Miller Bobcat 225 NT (what I began my present Biz with!)
            Miller 30-A Spoolgun
            Miller WC-115-A
            Miller Spectrum 300
            Miller 225 Thunderbolt (my first machine bought new 1980)
            Miller Digital Elite Titanium 9400

            Comment


            • #7
              Would he need to cut all of the damaged stuff out or can he overlap some of the damaged area with the patch? Obviously anything that is bent outwards needs to be dealt with but I'm just wondering if there is any reason to completely remove all of the damaged area.
              I've only ever done small repairs on pontoons, this job sounds fairly big!
              at home:
              2012 325 Trailblazer EFI with Excel power
              2007 302 Trailblazer with the Robin SOLD
              2008 Suitcase 12RC
              Spoolmatic 30A
              WC-24
              2009 Dynasty 200DX
              2000 XMT 304
              2008 Thermal Dynamics Cutmaster 52
              Sold:MM130XP
              Sold:MM 251
              Sold:CST 280

              at work:
              Invision 350MP
              Dynasty 350
              Millermatic 350P
              Retired:Shopmaster 300 with a HF-251

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              • #8
                jamscal,

                Your comment about plasma cutting the old/damaged areas out and welding new panels in bothered me a little.

                Think you're going to find that butt welding new panels to the old aluminum which was plasma cut is going to give you problems. The aluminum in the immediate area of the plasma cut is going to cause problems if not ground back about 1/4". May not be as much of a problem with a spoolgun, but with tig, that plasma cutline has given me problems in the past.

                You may want to think about a sabre (jig) saw vs the plasma. I use a Bosch jig saw and it does a great job on 1/8" aluminum. Also, tig has no problem with a saw cut cutline. For the time you save with plasma, you're going to loose it in grinding.

                Just my .02, but something to think about.
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                • #9
                  FusionKing: It's a Riveria Cruiser. That's all the info I have now.

                  KBar: It's out of the water most of the time, and has never been in saltwater. I did hear water sloshing inside when he pulled up with it though


                  C Wagner: I wondered the same thing. I may have to overlap if I run into a big problem where it doesn't want to butt weld, but we'll see.

                  SundownIII: Thanks for the tip on Plasma. I have a Bosch Jig saw as well and will probably go with that.


                  -James

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                  • #10
                    Riviera cruiser went out of biz a few years back
                    They were an .080 boat unless it's an older thinner one.
                    I usually patch over damage when I can so its double metal
                    You just need to decide what to do on a job to job basis 'cause they are all different in one way or another. That is untill they all start looking the same

                    www.facebook.com/outbackaluminumwelding
                    Miller Dynasty 700...OH YEA BABY!!
                    MM 350P...PULSE SPRAYIN' MONSTER
                    Miller Dynasty 280 with AC independent expansion card
                    Miller Dynasty 200 DX "Blue Lightning"

                    Miller Bobcat 225 NT (what I began my present Biz with!)
                    Miller 30-A Spoolgun
                    Miller WC-115-A
                    Miller Spectrum 300
                    Miller 225 Thunderbolt (my first machine bought new 1980)
                    Miller Digital Elite Titanium 9400

                    Comment


                    • #11
                      Oh yea...no foam in those unless somebody else done it.
                      Also a circular saw works awsome on aluminum.

                      www.facebook.com/outbackaluminumwelding
                      Miller Dynasty 700...OH YEA BABY!!
                      MM 350P...PULSE SPRAYIN' MONSTER
                      Miller Dynasty 280 with AC independent expansion card
                      Miller Dynasty 200 DX "Blue Lightning"

                      Miller Bobcat 225 NT (what I began my present Biz with!)
                      Miller 30-A Spoolgun
                      Miller WC-115-A
                      Miller Spectrum 300
                      Miller 225 Thunderbolt (my first machine bought new 1980)
                      Miller Digital Elite Titanium 9400

                      Comment


                      • #12
                        Well at least I don't feel bad now for using an overlapping panel repair.
                        We look forward to seeing the results of your repair!
                        at home:
                        2012 325 Trailblazer EFI with Excel power
                        2007 302 Trailblazer with the Robin SOLD
                        2008 Suitcase 12RC
                        Spoolmatic 30A
                        WC-24
                        2009 Dynasty 200DX
                        2000 XMT 304
                        2008 Thermal Dynamics Cutmaster 52
                        Sold:MM130XP
                        Sold:MM 251
                        Sold:CST 280

                        at work:
                        Invision 350MP
                        Dynasty 350
                        Millermatic 350P
                        Retired:Shopmaster 300 with a HF-251

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                        • #13
                          Overlapping is fine by me, if that's the way it's done.

                          I'm sure it's stronger. I was worried about the "Hydrodynamics" of the boat.

                          I'll see when I get into it.

                          Thanks to all.

                          -James

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                          • #14
                            Here are a few pics of the damage and started repair.

                            Had to get the rear in the air and stabilized, removed the 'runners' on the trailer, measured a few times for the cuts and then cut them out with an angle grinder, which was noisy but pretty fast.

                            I'm having the aluminum rolled tomorrow and will probably finish up Thursday when it's warmer.

                            The wall thickness is .080.

                            I am going to lap the panels over the holes.

                            Insides of the pontoons had a bit of water in them but looked good to me.

                            -James
                            Attached Files

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                            • #15
                              One last pic.
                              Attached Files

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