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Building a pontoon boat. Need to join numerous foam billets and cover them with something to reduce surface area. What would you do? Great stuff? EA40? Boat epoxy? Fiberglass tape? Pontoons are each 16’x1’x2’.

I have numerous billets of differing sizes. Thinking of joining them with dowels and epoxy and filling gaps with great stuff. Bonus question… Am I retarded? If so, why?

Building a pontoon boat. Need to join numerous foam billets and cover them with something to reduce surface area. What would you do? Great stuff? EA40? Boat epoxy? Fiberglass tape? Pontoons are each 16’x1’x2’. I have numerous billets of differing sizes. Thinking of joining them with dowels and epoxy and filling gaps with great stuff. Bonus question… Am I retarded? If so, why?

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[–] • 2 pts (edited )

small wooden dowels & glue to join the blocks, carve to shape, fiberglass mat, sand & finish prep, then epoxy gel coat.

The air holes in foam are what make it so buoyant. You don't want to fill them all. Filling the outside layer may be fine. but the foam is never going to be abrasion resistant itself

Decent vid if you've never done your own fiberglass. https://yewtu.be/watch?v=1Kf8IkJJbMw