Wilson Pontoons used for DIY Pontoon boat

Wilson Pontoons on boat 8' x 21'...work in progress

The pontoon boat build using Wilson ‘toons is progressing well despite cold winter conditions in Nelson, B.C.

The side rails are 4-inch aluminum C channel bolted into stainless steel inserts that come standard with the pontoons. The logs themselves are great, very hydrodynamically designed and the interlocking system is very tight and secure. 

The two snags thus far have been shipping costs from east coast U.S. to west coast Canada, i.e. about $1,800 so that will add quite a bit to the boat’s final price.
Second, the logs are heavy given that they are styrofoam filled and made from thick polyethylene. The nine-foot nose cones weigh a couple hundred pounds and the 12-foot aft modules even more. Plus, they’re awkward as hell to move around, so make sure you have help.

Ultimately, the boat will have rails all around plus a superstructure aft that will cover about half of the deck space. I intend to try outboards of different sizes to see what it takes to push the estimated 2,500-pound craft effectively in cruise and docking situations. We’re not into speed, so zooming around Kootenay Lake is not in the plans, but I don’t want something that won’t cut waves in wind or when entering the boathouse.

Will start with a Merc 9.9 hp Bigfoot and then work up to 15, 20, and 25 hp; I have a cooperative engine supplier!

Anyone wondering about a budget for a DIY pontoon boat, the logs, delivery, and brokerage fees total $6,000, aluminum $2,200, decking, floor, rails, and superstructure will be about $2,000, hardware $600, engine about $5,000, smoked plexiglass for fence, $1,500, furniture $3,000 for a total of $20,300. My experience suggests that I should add 10%, so let’s say $22,000. Add in a pontoon trailer for $4,000 and you get the picture.

I know…I could buy one already built for that….  

I’ve never built anything this big or mechanical before, so the journey is most of the fun, and thus far the build has been quite enjoyable for a winter project. I’ve never cut and drilled aluminum before, so working with four 20-foot rails and a couple of dozen cross members has been interesting. Lots of holes, bolts, washers, and nuts!! Launch date is expected to be early May 2014. Will update with more photos.