Pontoon Issue, cracked weld

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Eagle River Mike

Member
Last year while I was winterizing my pontoon boat, I heard a hissing noise. After searching around, it was coming from the left pontoon at the top of the rear where the end cap is welded on. The weld has a small one inch crack. I beach and park my pontoon everywhere so I could understand some damage on the bottom or sides of the pontoons but at the top really puzzles me. Anyway, gettting ready to put the boat back in and I need to get the cracked weld fixed even though it is way above the water line. Is this something I can try to fix with JB Weld or should I try to find a guy who can weld aluminum and get it fixed correctly. Also, if the weld is failing in this small area, am I going to have more areas fail or could this be an isolated issue? The boat is a 2003 Lowe Jamaican 200 that we have owned since new and have put about 500 hours on without a single problem. The Yamaha T60 four stroke runs as good as it did day one.
 
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yamaholic

Member
I've used JB weld alot on- cast pipe,radiators,water pump housings, never let me down it's all in the prep hand sand first real good. try it.
 
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scott_b

Member
I would spend the few extra bucks and have it welded. We had an old pontoon boat that the top weld cracked, we didn't fix it and the stress we exerted on other support points breaking them too. Went from one broken to 3 in the matter of months. Get it welded and never think about it again.
 
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Skidooski

New member
I had a leak on my pontoon right where the bracket for the fish locator transducer mounts. I had two attempts at having it welded neither worked. I finally did it my self with marine grade J.B. Weld. It's held up and I'm on my third year with no leak.
 
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anonomoose

New member
Jb will work to plug the leak but it won't do anything if the point is a stress crack and the crack will keep going. Actually this type of crack in pontooners is not uncommon. Aluminum does flex so it can be an on going thing. Also check all over really good too, because this might NOT be the only place where the weld failed. A good man who knows HOW to weld aluminum can fix it and keep the crack from growing. If they don't do it right, the weld will just fail again. If the point of the crack is stressed, then it might need some reinforcement to prevent further cracking.

All in how perminently you want to fix the crack....don't forget that even though it is on the top, that spot will let rain and wash in there and it can get really hot with direct sun hitting it daily.
 
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Eagle River Mike

Member
Dropped the pontoon off at BoatSports over the weekend. They are going to pressurize both pontoons to 3 or 4 PSI and then spray them with a soapy water mix and watch for bubbles. Then once all the leaks are identified, they will TIG weld them. It figured it was best to make sure there were no other leaks or failing welds while they had it. They said they woud have a $$$ estimate to me by the end of the weak.
 
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Eagle River Mike

Member
BoatSports found 4 leaks between the 2 pontoons and charged $180 to fix them all. They then re-pressure tested the pontoons and no more leaks. Best $180 I ever spent and they even dropped the boat back off by my garage. Great service and turn around time, espeecially this time of year!
 
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