We spent some time trying to get the pontoons to have an identical shape. It was a bit tough as we are are sculpting them individually. To solve the problem, we used a batten.
The batten provided us a fixed reference point off of which we had something to measure and sand the pontoon shapes with a good degree of uniformity.
In the photos below you can see how the batten is used and the steps involved in the process...
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| This is the port pontoon. The batten is visible. We cut a slot in the foam from the bow back about 5 feet. The batten is set in the slot and epoxied in place. On the starboard side and identical batten is used stretching from the same two exact points. |
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| On top of the 2 part foam we added spray foam to build up the shape we wanted. |
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| We then disk sanded down to the batten and from this edge we were able to form the correct shape. |
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Phenolic modified epoxy is then used to smooth out the rough sanded shape.
After the whole pontoon is coated with this material, an orbital sander will be used.
After the sanding we will then glass the surface and overlap the hull bottom to seal up the pontoon. |
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| To slowly remove the foam, we are using a variable speed sander set at the slowest rpm. This allows more control. |
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