Build

Choosing Pontoons & Deck

Choosing a platform, figuring capacity and picking a deck that will outlast the boat.

Capacity

Start with the manufacturer's rated capacity. Our first prototype began as a 24 ft Voyager rated for 1,800 lb, or 12 people. We removed 600 lb of furniture, carpet and railings and added 1,200 lb of cabin, interior, systems and rails. That left a 1,200 lb payload, or 8 people, still within the original rating.

Tube diameter matters most. A pair of 25 ft tubes at 24 in diameter supports 4,523 lb at 50% immersion; at 27 in, 5,726 lb. If your tubes are small, add a third center tube during the build.

Looking for a project boat? You want clean tubes, a solid outboard and a road-worthy trailer. Worn-out furniture is a bonus. We can also supply a new, fully decked platform ready for the cabin.

Pontoon sources

Chicago Pontoon Parts

Culver, IN · factory-surplus tubes up to 24 ft

Pontoon Logs and More

Columbia City, IN · surplus tubes, on Facebook

American Pontoon Company

Manning, SC · new tubes in all sizes, bolt-together kits

Tiny Pontoons

Concord, NH · full-size poly sectional pontoons

Deck material

Re-decking under a finished cabin isn't practical, so choose carefully now.

Material	Cost vs plywood	Notes
CCA treated marine plywood	Baseline	Industry standard. Replace unless nearly new; seal all penetrations and underskin.
Coosa composite	About 2×	Our pick. Never rots and is lighter than plywood. Through-bolt attachments.
Aluminum sheet or plank	About 2×	No rot, but heavier. 3/16 in sheet minimum, 1/8 in planks.
Composite deck boards	n/a	Don't.