1. Draw the 24” (61 cm) reference lines. 2. Draw the offset dimensions for panel drawings provided. Create curves. Double check yourwork before you cut! Be sure to draw the frame/bulkhead reference lines. For Top Panels, draw the reference lines ON BOTH SIDES OF THE PANELS. 3. Cut out one each of the top panel half, side panel half,bottom panel half, end bulkheads, and mid frame. 4. The pontoons are symmetrical. Use the items you cut out as templates for the remaining parts. 5. Butt block the short panels to form long panels.Use wooden butt blocks 10” (25 cm) wide. Be sure to bevel the edges of you butt blocks so the pontoons assemble correctly. 6. Stitch the floor and side panels together. Stitch the frames and bulkheadsto the reference lines drawn. Measure diagonals to ensure the pontoon is assembled square. 7. Apply masking tape to exterior pontoon seams. 8. Coat wood within 3” (7.6 cm) of all seams with resin. 9.Tack-weld the panels, frames, and bulkheads into place. 10. Remove stitches. Remask exterior seams as needed. 11. Fillet and apply fiberglass tape to seams. Spread excess resin from glass onto interiorbare wood. Ensure all interior wood has 2 coats of resin total. 12. Cut ½” (1.3 cm) strips for tops of frames and bulkheads to form T -cleats. Glue cleats into place on top of frames and bulkheads.13. Flip pontoons. Remove masking tape. Grind/sand a radius on exterior seams. A more rounded seam will be easier to apply fiberglass tape to. 14. Fill in any cavities or voids. 15. Coat wood within 3”(7.6 cm) of all seams with resin. 16. Apply fiberglass tape to seams. Spread excess resin onto bare wood. Ensure all wood has 2 coats of resin.
1 of 3
These instructions and its concepts may not beused, resold, reproduced, or distributed except as specifically directed by JEM Watercraft.
Pontoon Build Instructions Rev 00 – 06/16/04 JEM Watercraft
17. Flip pontoons upright. Grind a...