How to Build a Pontoon Boat Out of Oil Barrels

Preparing the Timber

• 1

  Stretch your wooden timber along the ground forming a 10-foot by 8-foot rectangle. The 10-foot timbers are parallel as one 8-foot timber lays across each end.

• 2

  Use the tape measure to find the center of the rectangle and lay the third 8-foot timber in the middle of the rectangle.

• 3

  Use the marker to outline on the 10-foot timber where the 8-foot timber rests at each end and the middle section. Make the same outline on the 8-foot timber where it overlaps with the longer timber.

• 4

  Measure half the thickness of the 8-foot timber, marking it to be cut. The cut will be made from the bottom up.

• 5

  Measure the halfway point of the 10-foot timber thickness marking it to be cut. The cut will be from the top downward.

Cutting the Timber

• 6

  Set up your table saw to the depth of marks for the notches to be made in the timber.

• 7

  Make your cuts at 1/8-inch increments until you reach the marker lines. Chisel away any excess to prevent from over-widening the notches.

• 8

  Repeat Step 2 for each notch. Fit the timber back together in the rectangle securing the pieces in place with the notches. Draw a 2-inch square with your marker and carpenter's square above the notches of the 8-foot timber. The 8-foot timber acts as a connector for holding the rectangle together.

• 9

  Put the 1/2-inch countersink bit on the drill. Place the drill bit at each notch point. Make a hole at each corner of the 2-inch square drilling through both the 8-foot and 10-foot timber. Countersink the hole deep enough to allow the bolt head to lay flush on the timber.

• 10

  Put a washer on the bolts pushing each of them through the drilled holes in the timber. Place a second washer on the opposite end of the bolt. Screw a nut to the end of each bolt, tightening each by hand.

• 11

  Place the carpenters square flat against all the beams to ensure your frame is square. Tighten the bolts holding the head with your wrench and screwing the nut in place by hand.

Making the Platform

• 12

  Lay each of three plywood panels side by side across the frame. Space the panels 3 inches apart. Tack the panels in place with galvanized nails at the center of each timber on the frame. The panels create the deck. Flip the frame over facing the deck downward.

• 13

  Line four oil drums in place along the length of one 10-foot side of the platform. Secure the drums in place flush against the outer edge of the frame temporarily with wooden blocks -- or shims.

• 14

  Create a reference line by placing a mark on the deck's underside beside each corner of the drum. Mark the corners of each drum lining the side. The marks will provide the location for seams attaching the oil drums to the frame. Remove the drums.

• 15

  Create cleats -- fastening points -- by cutting two slots into the timber with a jigsaw at each of the marks you made. Each cut should be 2 1/4-inch wide and spaced the same distance apart.

• 16

  Repeat steps 2, 3 and 4 on the opposite side of the frame. Place the drums in two lines of four spreading them eight feet apart. Hold the drums in place with the blocks.

• 17

  Place two ratchet straps under each drum. Put the ratchet end outside the lines of your seam -- 2 1/4 inch grooves cut into the timber -- placing the straps within the seams.

• 18

  Laying the deck atop the drums, align the center beam to pass between the middle two drums on each side of the platform.

• 19

  Slide the ratchet straps on the drums through the slots cut into the underside of the deck. Feed each strap into the ratchet and tighten as firmly as possible making sure your straps are secure and inside the drum seams.

• 20

  Fill cavities or voids with excess wood. Coat any wood within three inches of your seams with resin.