Rebuilding The Boat With Coroplast & Studs

From YouTube: In the last episode, we were hit by a snowstorm that dumped so much snow on the Sputter Butt that it caved in the top of the boat. It was a complete loss. As soon as the weather improved in the Spring we began rebuilding.

Weight is definitely a concern since the pontoons on this boat are considerably smaller around than most pontoon boats this size. We decided to just build it like it needed to be built and then add a third pontoon or plastic barrels if needed.

We’re covering the boat with Coroplast. It’s waterproof, inexpensive and easy to use. We’re also adding a small galley and a small head.

The actual trip down the Tennessee River will be challenging and getting the boat in shape for the trip has been a challenge in itself.

Originally posted 2016-04-27 06:19:25.

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  1. The mistake they made in the beginning was trying to put a house on something that was designed to be a lightweight deck boat. That haunts them through the whole project.
    There is a reason that nobody uses coroplast as building material. It’s unsuitable, and again it haunted them through the whole project. The put many hours of hard work and many $$$ into it. They would have been off using “camper technology” (like they did with the 2×2 studs which was good) and applied 1/8″ luan and covered with filon (.030 fiberglass sheet). It’s pretty lightweight and would have been stronger and more durable. And get rid of that grey emt tubing for the roof! They could have made lightweight ribs out of 1/4″ ply. It’s sad because they toiled for many hours on it. They videos seem to just stop so I don’t whatever happened to it. Perhaps the lesson learned from this would be, “If you can buy your building material at an office supply store, you may wish to re-think it’s use as a major ingredient in your boat project”.

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