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  1. #1
    Join Date
    Mar 2007
    Posts
    132

    Default 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. #2
    Join Date
    Sep 2005
    Location
    Salem ,Ohio
    Posts
    3,909

    Cool

    I have seen a few with foam sprayed inside the tubes...Bob
    Bob Wright, Grandson of Tee Nee Boat Trailer Founder
    Metal Master Fab Salem, Oh 44460
    Birthplace of the Silver & Deming Drill
    1999 MM185 w/185 Spoolgun,1986 Thunderbolt AC/DC
    Spool Gun conversion. How To Do It. Below.
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  3. #3
    Join Date
    Nov 2006
    Location
    Lake of the Ozarks MO
    Posts
    3,562

    Default

    Quote 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.

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  4. #4
    Join Date
    Mar 2007
    Posts
    132

    Default

    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

  5. #5
    Join Date
    Jul 2007
    Location
    Lancaster, Pa
    Posts
    431

    Default

    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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  6. #6
    Join Date
    Nov 2006
    Location
    Lake of the Ozarks MO
    Posts
    3,562

    Default

    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 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)
    SPEEDGLAS 9100XX

  7. #7
    Join Date
    Nov 2007
    Location
    Saskatoon, Sask, Canada
    Posts
    1,270

    Default

    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:
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    at work:
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