- 1). Lay three of your plastic barrels end to end. Mix your two-part adhesive epoxy according to the manufacturer's instructions. Coat both ends of the middle barrel with epoxy. Push the outer barrels against the center barrel to bond all three into one pontoon. Repeat the process with your remaining three barrels to form the other pontoon. Apply marine grade caulk along each seam between the barrels.
- 2). Place the pontoons on the ground 6 feet apart and parallel to each other. Lay three sheets of marine-grade plywood across the top of the pontoons. Drill holes through the plywood and into the wood with the 1/2 inch bit on your drill. Slide a washer onto each bolt. Twist a butterfly nut onto each bolt. Push the butterfly nut through the hole in the wood and into the barrel. Twist the bolt tight. Snug it with your adjustable wrench.
- 3). Repeat this process every 12 inches along each board to fasten the deck onto the pontoons. Apply a liberal amount of marine-grade caulk onto the head of each bolt to prevent leakage. Cover the top of the deck with construction adhesive. Spread the adhesive with a plastic putty knife. Cover the deck with a piece of AstroTurf. Roll the AstroTurf smooth with a wallpaper roller. Let the adhesive dry overnight.
- 4). Hold the motor mount in the center of the aft, or rear, part of the deck. Push the tip of your marker into each retaining hole in the mount to mark the deck. Set the mount aside. Drill a hole in the deck at each mark. Hold the motor mount onto the deck, line it up with the holes and secure it with butterfly bolts. Snug each bolt with your adjustable wrench.
- 5). Slide your motor onto the mount. Twist the handle of each retaining bolt on the motor to lock it in place.
next post