Well last weekend as some of you know I aquired a motorless 24' pontoon boat. As most of you know I'm not really a toon fan mainly from the towing aspect of it. I have to tow atleast an hour in any direction to dump one in the water. Atleast 2 hours to dump one in a lake with some good catfishing. I have always wanted to do a project toon just to see what I could come up with. Kind of like wanting to build a racing sailboat even though I dont give a flip about sailing or care to learn. The toon is a 1977 Riveria Cruiser. It's seen better days but is a sound toon to this day. It's days will become better and better. It had already been stripped of furniture and was basicly a carpetless wood deck with a console and railings. I wouldnt have it any other way for a project boat. Less to unbolt and haul to the dump. I piddled on cleaning a pontoon for about 3 hours last Sunday basicly getting the feel for how the thing was put together and compiling a mental to do list. I crawled under and over it while getting my thought processes going. This week I put together two devices to screw in the drain holes of the toons complete with gauges so I can put 3 pounds of air in each toon and use some leak detect on the outside of the toon to find any leaks. With the gauges I can monitor any air pressure loss between the days I work on it. Last night and this morning I went shopping for shop supplies. I bought grinding wheels, cutoff wheels and abrasive disks for my right angle grinder. I bought a gallon of aluminum cleaner that can be dialuted with water. This stuff is awesome. I bought some paint remover to help loosen up the bottom paint that was put below the waterline. And I bought another toolbox. I buy a new 19" toolbox for every project I have going. Some projects have 2 boxes. I buy the same kind every time. 8 bucks and change at Lowes and has a removeable tray. I keep my project essentials in these boxes like grinding wheels, drill bits, sawzall blades, counter sinks, and small pieces I dont want to loose. I'm going to totally rebuild this toon from the trailer up. It will come completely apart and every nut and bolt in it will be changed to stainless in the process. Today I removed the railings. I wound cutting just about every bolt with a right angle grinder and cut off wheel. It saved alot of busted knuckles, cussing , and damage to parts I want to reuse like the railings and deck skirt. They are a must for boat remodeling and boat building. Mr. Grinder is my friend. Next I removed all the wiring from the pontoon and the console. Then the steering cable and what was left of the captains seat. Bobpaul, I'm still waiting for you to tell me what you'll knock off for those dents and the broken captain's chair.:big_smile: And today I sprayed down the outside of the pontoons with the acid cleaner. Yep, there is aluminum under that scum and oxidation. Tomorrow , I hope to get the deck off and map the crossmembers and get them removed, cleaned up and touched up with some galvanized primer. that will leave me with two pontoons and some body work. At some point these pontoons were damaged being winched onto the trailer from dry ground or by a forklift at a boat motel. There is a dent on the bottom of each pontoon about a foot from the stern. I'm going to try to pull these dents which will require drilling holes in the toons but thats what they make tig welders for.:big_smile: Once I get any leaks identified and fixed I'll polish the toons. The redecking I'm still mulling over. I would rather save some weight in redecking even if its only 50 pounds. I know I wont be going back with treated 3/4" plywood and I know I wont be going back with marine plywood. There really isnt any need to. If it were a boat hull and submersed in water I would. I'm leaning towards some nice 5/8" exterior plywood. I'll glass the bottom of each panel with 12 oz biaxial fabric and epoxy. Once I get each panel installed I'll glass the whole topside in with 6 oz biaxial fabric and epoxy. This deck will last well beyond me and be real strong. You could play football with scuba tanks on it. I'll probally opt for marine vinyl for a floor covering. My preference is Seadek but Seadek will run me right at a 1000 dollars to cover it versus 350 or so for vinyl. Seadek is a nice product. Easy on the feet and easy clean. Oh well, not this time around. Using Seadek I was intending to inlay the BOC logo in the middle of the floor. Its a cut, peel, and stick product. I'll be building a new console. Wider and a little taller. I plan to put built in tackle drawers in the front and sides of the console. I'm already in the design phase of this console. Right now I'm trying to design in the lid feature. To access wiring and the inside of the console I can remove the tackle drawers or flip the whole top open like a hatchback. I'm hoping that my washdown pump, pressure tank and filter will fit in the bottom of the console. I need to get the measurements of that unit to plan for it. The stern of the pontoon boat. The aluminum transom is cracked. Thats no big deal as this is a 2 piece aluminum transom with 2 pieces of 3/4 plywood sandwiched inbetween. The new transom will be all aluminum. Other then the transom itself the whole back end of the pontoon will be scrapped and a new one rebuilt to hold the batteries and fuel tanks. I want to build a simple engine cover that clips into place over the engine to divert the noise from the engine rearward. I have a 2 stroke 60 horse that Bobpaul has been going over with a fine tooth comb so its not the quietest thing available but its paid for except for the bill Bobpaul gives me. While I'm talking about the transom I want to mention treated lumber and aluminum. The two dont go together. People say its the new stuff that is the problem but I beg to differ. This transom could have been repaired but the pitting on the aluminum plates that were against the treated lumber is bad. Real bad. I wouldnt put a piece of treated lumber old or new anywhere near an aluminum boat. Copper sulphate is one of the wood preservatives. Copper and aluminum are two dissimilar metals. They will attack each other. Aluminum just isnt the best material to build boats out of from several standpoints but I have 2 now:crazy: The trailer. Was built in a welding shop I believe here in NC. Its a steel trailer and appears to be well built and sturdy. I'll strip it, prime it and paint it. I want to attempt a few things like raising the trailer lights in the rear up onto some guide ons. I also want to put wheel fenders over the tandem axle. Pulling it in a rain or on wet gravel pack road leading to a boat ramp would make one big mess. I had actually considered mounting the trailer lights to the pontoon boat itself using just a plug and go feature. It's still a possibility and I'll go down that road when I get to it. I would probally have alot less problems from water and road shock. This was just my opening salvo. There will plenty more to follow as I'm going to try using several different products I've never used before like the vinyl flooring. I'll do the tests with the adhesives on the epoxy that I use and all along I'll be throwing in some miscellaneous accesories that I build or buy. I will go ahead and tell you I have one item I picked up over a year ago sort of as a premonition of owning a pontoon. Its a 12 volt coffee maker with a 8 cup capacity I think. I couldnt pass it up at Boater's World for 12 bucks.:lol: I'll start getting some pictures up tomorrow evening. There isnt a whole lot to look at other then to see what it looks like. Taking a pontoon this old apart is proving to be more difficult then building a boat from scratch.