How to Build a Metal Pontoon

A metal pontoon is useful as a floating dock or island in a lake, or a motor can be attached so it can be used as a vessel. The air in the metal containers keeps the structure afloat, while the decking on top offers a place to sit or relax. More pontoons can be lashed together to make larger structures of even bridges.

Things You'll Need

  • Airtight metal drums
  • Safety gloves
  • Heavy gauge wire
  • Wire Cutters
  • 2-inch by 6-inch lumber
  • 2-inch by 2-inch lumber
  • Tape measure
  • Saw
  • Nails
  • Hammer
  • Drill
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Instructions

  1. Making The Pontoon

    • 1

      Assemble nine clean airtight metal drums (the standard 55 gallon drum is ideal, as long as it’s in good shape, with a cap and rubber seal). Test whether each one is airtight by putting in a tank of water and checking whether it floats without sinking after a few minutes.

    • 2

      Arrange the drums the three rows of three tanks. Put on safety gloves, then wrap heavy gauge wire tightly three times around one on the tanks, approximate 12 inches in from one end, then extend the wire to wrap three times around the next tank the same number of times. Cut the wire with the wire cutters and wrap the end around the wires to create a tight knot. Repeat at the other end of the drum.

    • 3

      Wrap wire around the second of the two drums you’ve just joined and attach to the third in the same manner. Repeat with the other barrels until you have three sets of three barrels lashed together. Lines the drums up so you have three ranks of three drums.

    • 4

      Wrap wire around the wire that connects the left and middle drums of the front row. Thread the wire lengthwise under the middle drum and then wrap it around the wire connecting the middle and right drums of the back row. Wrap tightly and cut the wire. Repeat on the other diagonal.

    Making The Deck

    • 5

      Measure and cut the 2-inch by 6-inch lumber to create a deck slightly larger on all sides than the metal pontoon. Cut four lengths of 2-inch by 2-inch lumber that are 4 inches shorter than the width of the deck (that is, the planks placed side by side); these will be the deck supports. Nail the supports across the deck, nailing downward from the deck and begin certain no nail points protrude below the supports.

    • 6

      Lay the completed deck on top of the pontoon, positioning it so the deck supports are across the width of the drums. Mark a point on the front support between the left and middle drum and between the middle and right drum. Remove the deck, and drill through all four support at the point. Replace the deck on top of the pontoons.

    • 7

      Wrap wire around the wire connecting the bottom of the left and middle drums at the front of the pontoon. Feed up and through the holes in the supports, then down to the wire connecting the back of the drums. Wrap tightly and cut. Repeat between the middle and right drums.

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