Locate where storage areas, the live-bait well and the beverage cooler will be located.
Measure the length of the gunwales from the transom to the prow.
Measure the length of the transom and the prow.
Locate where the anchor and anchor rope will touch the deck.
Determine how long the fore deck, aft deck and middle deck will be.
Mark three 2-inch-by-2-inch boards at the inside length of the gunwales and use the circular saw to cut them to size.
Paint the cut boards with wood sealer and set aside to dry.
Mark one 2-inch-by-2-inch board to the width of the transom, minus the width of the two gunwale braces and use the circular saw to cut it to size.
Mark one 2-inch-by-2-inch board to the width of the prow minus the width of the two gunwale braces and use the circular saw to cut it to size.
Paint the cut boards with wood sealer and set aside to dry.
Apply marine adhesive sealant to the first 3 feet of one of the gunwale braces.
Clamp the first 3 feet of the gunwale brace into position, beginning at the bow, inside the boat, using the four C-clamps.
Drill pilot holes through the boat hull into the gunwale brace every 4 inches. If a clamp is in the way, move it slightly and re-tighten it before drilling.
Working from the bow, install screws through the hull into the gunwale braces. Release the C-clamps.
Apply marine adhesive sealant to the next 3 feet of gunwale brace and clamp in place. Install screws as before.
Repeat the process of moving the clamps, applying the marine adhesive sealant and driving screws until the entire gunwale brace is installed.
Use your circular saw to cut the plywood to a length equal to the length from the bow to the end of the fore deck. This is where your fishing chair mounts, so leave enough room for your feet in all directions.
Lay the cut plywood on the front of the jon boat so that it is even with the prow and square to the sides. Weight it down so that it will not move.
Draw a marker line on the plywood, tracing the hull line on both sides of the hull. Mark the gunwale braces where the fore deck ends.
Turn the fore deck over and use the jig saw to cut off any edges that extend outside of the boat.
Attach 2-inch-by-2-inch bracing boards perpendicular to the keel on the down side of the deck. Be sure the bracing boards are cut slightly shorter than the deck's width so they don't stick outside of the hull. Cut as many bracing boards as you need to space them 12 inches apart under the deck, with the first one 12 inches back from the prow. Attach the bracing boards to the underside of the deck with resin and hardener brushed onto fiberglass tape, cut to fit with the razor knife or scissors. Tamp the fiberglass down firmly with the fiberglass roller. Use the acetone for clean up.
Paint the fore deck with wood sealer and set aside to dry.
Clean the area of the gunwale braces where the hull is to attach with a dry rag.
Apply marine adhesive sealant to both gunwales and the prow, from the bow to where you marked the aft end of the fore deck.
Turn the fore deck right-side-up. Lay it over the prow and forward parts of the gunwales. Jiggle it into position and weight it down so it does not move.
Attach the fore deck to the gunwale and prow braces by drilling pilot holes and driving screws down through the fore deck into the braces.
Make a deck brace out of a 2-inch-by-2-inch board and install it amidships on the edge of the aft part of the fore deck. You can eliminate this step if one of the fiberglassed braces was located exactly at the aft edge of the fore deck.
Make a 2-inch-by-4-inch brace from the under side of the deck to the keel. Install with marine adhesive sealant at the aft end of the fore deck.
Repeat this process to make and install the aft and middle decks.
Cut industrial flooring or diamond plate to fit the area where the anchor is used. Install it with marine adhesive sealant.
Cut holes in the deck for the beverage cooler, live-bait well and storage locker. Drop in the units or install a permanent storage hatch with screws and marine adhesive sealant.
Install boat chair(s) according to the manufacturer's instructions.
Cut indoor-outdoor or marine carpeting to fit the deck. Install the carpeting with marine adhesive sealant. Weight the carpet to keep it in place until the adhesive dries.
