Instruction Manual for POND KING models including: Own Boat, Own Boat Pontoon Boat Kit, Pontoon Boat Kit, Boat Kit
DIY Mini Pontoon Boat Kit | Mini Pontoon Boat | Pond King – Pond King, Inc.
BUILD YOUR OWN BOAT + Assembly Instructions Thank you for purchasing the Build Your Own Boat + pontoon boat kit. This size boat is best suited for smaller bodies of water without heavy wave action. Boats built outside these recommendations will void all warranty. Here is how we recommend you build your deck and finish out your pontoon boat. What You'll Need: Recommended Materials: · Circular Saw · Cordless Drill · 1/4" Drill Bit · 3/8" Drill Bit · Measuring Tape · Chalk Line or Marker · 7/16" Wrench and Socket · (7) 8' Pressure Treated or Marine Grade 2" x 4"s · (1) 4' x 8' x 1/2" sheet of pressure treated or marinegrade plywood · (72) 2-1/2" Spax Exterior Wood Screws · 9/16" Wrench and Socket · Utility Knife · Ear & Eye Protection · A friend to help hold/lift pieces First, you'll build the frame. Step 1: Cut all 2x4 boards and plywood to length. 2"x4" Boards: Plywood: (2) @ 90" (1) @ 93" x 46" (7) @ 43" (2) @ 46" Step 2: Arrange the 90" and 46" 2x4s to form the perimeter of the frame. The 46" board will be on the outside of the 90" boards making your overall length 93". What's Included: · (4) Pontoons · (6) Piece Railing Kit · (1) Trowel · (1) Tub of Carpet Glue · (1) Roll of Pre-Cut Carpet · (1) Transom & Spacer Pontoons-to-Deck Hardware: · (8) 3/8" x 4" Galv. Bolts · (8) 3/8" Flat Washers · (8) 3/8" Lock Washers · (8) 3/8" Nuts Transom Hardware: · (2) 3/8" x 4.5" Galv. Bolts · (4) 3/8" Flat Washers · (2) 3/8" Lock Washers · (2) 3/8" Nuts Rail-to-Rail Hardware: · (6) 1/4" x 2" Hex-Head Bolts · (6) 1/4" Locking Nuts Rail-to-Deck Hardware: · (12) 3/8" x 2-1/2" Hex-Head Bolts · (12) 1/2" Flat Washers · (12) 3/8" Lock Washers · (12) 3/8" Nuts If you have any questions, please don't hesitate to contact us by phone at: (940)668-573 BUILD YOUR OWN BOAT + Assembly Instructions Continued Step 3: Screw the perimeter together at the four corners using 2 screws on each corner as shown in Figure 1. **Make sure to pre-drill the holes first to avoid wood splitting!** Step 4: Mark the 93" lengths for placement of the cross-bracing boards indicating the center of the 2x4 cross-braces. Mark at these measurements from each end, measuring from the outside of the frame. See Figure 2. 10.5" | 22.5" | 34.5" | 46.5" Step 5: Arrange the (7) 43" boards inside the perimeter, lining the center of the board up with your mark as shown in Figure 2. Measure each diagonal of the permiter to make sure your frame is square. Adjust as necessary until you get matching numbers for both diagonals. Step 6: Make sure the boards are straight and flush with the top of the perimeter. Pre-drill holes or use self-tapping screws, and attach using 2 screws on each end. Measuring from each corner 10.5" 22.5" 34.5" 46.5" FIGURE 1: Perimeter Corner 90" Board 46" Board Attach with screws 46.5" 34.5" 22.5" 10.5" FIGURE 2: What your finished frame should look like Now, you're ready for the deck. Step 7: Lay the cut sheet of plywood on top of your frame making sure all edges are flush. Once you have it in place, screw down each of the 4 corners to keep it from moving around. Step 8: To fully secure the deck, you need to add more screws in the middle. So you know where the bracing is, make a grid and mark it with either a marker or chalk line. You will use the same measurements for the 93" sides as you did when building the frame. 10.5" | 22.5" | 34.5" | 46.5" To make your marks on the 46" sides, use these measurements from each corner: 11.5" | 23" Step 9: Use a straight edge and marker or a chalk line to make your lines across the plywood as shown in Figure 3. FIGURE 3: Making chalk lines Step 10: Use screws to attach the plywood at each of the intersections of your lines as shown in Figure 4. FIGURE 4: Attaching the plywood If you have any questions, please don't hesitate to contact us by phone at: (940)668-573 Next, you'll install the carpet.. Step 11 : Using the trowel, spread a thin, even coat of carpet glue to the plywood deck as shown in Figure 5. Step 12 : Center the carpet at the 46" end of the deck leaving a little over lapping on each side. Roll out the carpet so it's covering the entire deck as shown in Figure 6. Step 13 : As you can see in Figure 7, use a pipe or other similar object, and press firmly to roll out any bubbles in the carpet and make sure it's adhered to the plywood. Step 14 : Take a utility knife and carefully trim the excess carpet so it's flush to the edge of the deck as shown in Figure. 8 FIGURE 5: Applying the glue FIGURE 6: Laying the carpet FIGURE 7: Rolling out the carpet Now it's time to assemble and install the railing. Step 15 : Lay the sections of railing onto the frame as shown in Figure 9. They'll only fit one way. Step 16 : Bolt the railing together using the included 1/4"x2" Hex-Head bolts and lock nuts. Use a 7/16" socket & wrench to tighten as shown in Figure 10. Step 17 : Next, you'll bolt the railing to the deck. Using a 1/4" drill bit, drill through the pre-punched 1/4" holes in railing into the 2"x4" wooden deck frame. Bolt the railing to the deck using the included 3/8"x2-1/2" Hex-Head bolts, 1/2" washers, 3/8" lock washers and 3/8" nuts. FIGURE 8: Trimming the carpet FIGURE 9: Arranging the railing FIGURE 10: Bolting the railing Next, you'll attach the pontoons to the deck. Step 18 : Arrange your pontoons to be the four corners of your boat and set your deck on top of it. Use a piece of wood to chock the pontoons so they don't roll away on you. The frame should fit in between the bracket and the square tube spacer. The short edge of the deck should be flush with the ends of the brackets on the pontoons as shown in Figure 11. FIGURE 11: Attaching the pontoons Drawing is not to scale. End of deck should line up with end of brackets. Step 19: Attach the pontoons to the deck using a 9/16" wrench and socket and the (8) sets of bolts, flat washers, lock washers and nuts as shown in the Bolt Flat Pontoon Deck Washer Bracket Square Lock Nut Tube Washer Spacer diagram on the left. You're almost there! Last, but not least, you'll attach the transom to the deck! Step 20: Center the transom on one end of your deck frame. Make the bottom of the transom flush (even) with the bottom of the deck frame. Step 21: Using a 3/8" drill bit, drill through the pre-drilled holes on the transom mount into the deck frame 2"x4". Step 22: Following the diagram below, bolt the transom to the deck frame using the included 3/8" x 4.5" Hex-Head bolts, 3/8" flat washers, 3/8" lock washers, and 3/8" nuts. We've included a spacer so the transom sits flat. Secure with a 9/16" socket and 9/16" wrench. See Figure 12. FIGURE 12: Mounting the transom Bolt Flat Transom Angle Deck Flat Lock Nut Washer Spacer Washer Washer Congratulations! You are now ready to use your brand new pontoon boat! DIY Boat Seat Mount Placement 27" Not to scale! 27" When adding your own seats to the boat, the center of the seat mount should be positioned 27" from the end, and centered, left to right.Acrobat Pro 23.3.20269 Acrobat Pro 23.3.20269