POND KING TRUE DIY Mini Pontoon Boat Kit Instruction Manual

POND KING TRUE DIY Mini Pontoon Boat Kit

Product Information

Assembly Instructions
The TRUE DIY PONTOON BOAT is a pontoon boat kit that allows you to assemble your own pontoon boat. The kit includes all the necessary materials and tools to build the boat frame and deck. The boat frame is made using 2×4 boards, and the deck is made using a 4′ x 8′ x 1/2 sheet of plywood. The pontoons are not included in the kit and need to be arranged separately.

Product Usage Instructions

Building the Frame:

1. Step 1 : Cut all 2×4 boards to the following lengths:
   • (2) @ 90″
   • (7) @ 43″
   • (2) @ 46″
2. 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 the overall length of the frame 93″.
3. Step 3: Screw the perimeter together at the four corners using 2 screws on each corner.
4. Step 4: Mark the 93″ lengths for placement of the cross-bracing boards indicating the center of the 2×4 cross-braces. Mark at the following measurements from each end: 10.5″, 22.5″, 34.5″, 46.5″.
5. Step 5 : Arrange the (7) 43″ boards inside the perimeter, lining the center of the board up with your marks. Measure each diagonal to ensure the frame is square. Adjust as necessary until both diagonals have matching numbers.
6. Step 6: Make sure the boards are straight and flush with the top of the perimeter. Pre-drill holes or use self-tapping screws to secure the boards using 2 screws on each end.

Building the Deck:

1. Step 1: Cut the 4′ x 8′ x 1/2 sheet of plywood down to 93″ x 46″.

2. Step 2: Lay the plywood on top of the frame, ensuring all edges are flush.

3. Step 3 : Screw down each of the 4 corners of the plywood to keep it from moving.

4. Step 4: Create a grid on the plywood to mark the locations for additional screws. Use the same measurements as you did when building the frame: 10.5″, 22.5″, 34.5″, 46.5″ for the sides and 11.5″, 23″ for the ends.

5. Step 5: Use a straight edge and marker or chalk line to make lines across the plywood according to the grid.

6. Step 6: Use screws to attach the plywood at each intersection of the lines.
   Attaching Pontoons and Motor Mount (if applicable):

7. Step 7: Arrange your pontoons to be the four corners of your boat and set the deck on top of them. 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.

8. Step 8 : Pre-drill 3/8″ holes in the 2x4s where you will bolt the brackets to the pontoons indicated by the existing holes in the brackets.

9. Step 9: 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.

Note:
If you have purchased the kit with a motor mount, please refer to the additional instructions provided for installation.

What’s Included

• (4) 5’L x 14” Diameter Pontoons
• (8) 3/8” x 4” Galv. Bolts
• (8) 3/8” Flat Washers
• (8) 3/8” Lock Washers
• (8) 3/8” Nuts

If you purchased the motor mount

• (1) Transom & Spacer
• (2) 3/8” x 4-1/2” Galv. Bolts
• (4) 3/8” Flat Washers
• (2) 3/8” Lock Washers
• (2) 3/8” Nuts

Recommended Materials:

• (7) 8’ Pressure Treated or Marine Grade 2” x 4”s
• (1) 4’ x 8’ x 1/2” sheet of pressure treated or marine-grade plywood
• (72) 2-1/2” Exterior Wood Screws (Spax recommended)

Recommended Tools:

• Circular Saw
• Cordless Drill
• 3/8” Drill Bit
• Measuring Tape
• Chalk Line/Marker
• 9/16” Wrench and Socket
• Eye & Ear Protection

Assembly Instructions

Thank you for purchasing the True Do-It-Yourselfer pontoon boat kit. In the boxes, you are receiving (4) pontoons and the hardware to attach to the deck you are going to build. If you purchased the optional trolling motor mount, it and its hardware are in a separate box. The pontoons are designed to fit a boat that has a finished deck size of 4’x8’. 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.

First, you’ll build the frame.

1. Step 1: Cut all 2×4 boards to these lengths: (2) @ 90” | (7) @ 43” | (2) @ 46”
2. 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”.
3. Step 3: Screw the perimeter together at the four corners using 2 screws on each corner as shown in Figure 1.
4. Step 4: Mark the 93” lengths for placement of the cross-bracing boards indicating the center of the 2×4 cross-braces. Mark at these measurements from each end. See Figure 3. 10.5” | 22.5” | 34.5” | 46.5”
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 to make sure your frame is square. Adjust as necessary until you get matching numbers for both diagonals.
6. Step 6: Make sure the boards are straight and flush with the top of the perimeter. Predrill holes or use self-tapping screws. Secure using 2 screws on each end.

FIGURE 3 : Your finished frame, also showing the measurements needed to mark for your cross-bracing.

Now, you’re ready for the deck.

1. Step 1 : Cut the 4’ x 8’ x 1/2” sheet of plywood down to 93” x 46”

2. Step 2 : Lay the plywood on top of your frame making sure all edges are flush.

3. Step 3: Once you have it in place, screw down each of the 4 corners to keep it from moving.

4. Step 4: 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”

5. Step 5: Use a straight edge and marker or a chalk line to make your lines across the plywood as shown in Figure 4.

6. Step 6: Use screws to attach the plywood at each of the intersections of your lines as shown in Figure 5.

7. Step 7: Arrange your pontoons to be the four corners of your boat and set your deck on top of it. 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 6.

8. Step 8 : Pre-drill 3/8” holes in the 2x4s where you will bolt the brackets to the pontoons – indicated by the existing holes in the brackets.

9. Step 9: 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 below.

If you’ve purchased the kit with motor mount, follow these instructions for installation.

1. Step 1: 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.
2. Step 2: Using a 3/8” drill bit, drill through the pre-drilled holes on the transom mount into the deck frame 2”x4”.
3. Step 3: Following the diagram to the right, bolt the transom to the deck frame using the included 3/8” x 4-1/2” 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.

DIY Boat Seat Mount Placement

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.

If you have any questions, please don’t hesitate to contact us.
Phone: 940-668-2573
Email: marketing@pondking.com

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