Pontoon Construction

Our Strong Foundation

In pontoon construction, it's the things you don't see that add up to better performance today and durability that lasts for years. In every aspect of a Sylvan, you'll find better materials, stronger designs, more fasteners, and more points of reliable fusion. All to give you the ultimate peace of mind.

CROSS CHANNEL CONSTRUCTION Provides superior chassis strength. The transom area is supported with up to 3/16" hat-channel construction using twice the amount of fasteners as other pontoons. This provides the strength needed to handle the high torque of today's large engines.

DOES YOUR BOAT HAVE OUR CONSTRUCTION? Other manufacturers use C-channel designs which can require more cross members and provide less strength than Sylvan’s hat-channel construction. And with imbalanced weight distribution, C-channel cross-members are less able to withstand the forces exerted on the pontoon year after year.



Constructed by Endurance - 3/4", 7-ply pressure treated plywood through=bolted and screwed to the hat channels to create the strongest seams in the industry

Hat-Channel Construction - How does Sylvan build the widest base in the industry without adding extra weight?  We use points of "heavy" .250 gauge (shown) and .125 gauge (standard), 6" wide aluminum hat channels and secure them by spreading 8 bolts across 6" wide deck risers.  We combine that with a .190 guage aluminum transom, through-bolted with up to 20 bolts and footed deck risers to eliminate tube fatigue.  We're so confident that our construction is the best in the industry that we back it with a Limited Lifetime Warranty. 

Fence & Railing - We back our fence and railing with foam to prevent rattling, but only after fully welding and anodizing every joint.  Once a weld is anodized, it is never painted.  Every foot of fence and railing is backed by a 6-year warranty.

Thru-Bolted Transom - Sylvan transoms are made from aluminum gauges as heavy as .190, and are supported with up to 20 stainless steel boats - all to handle today's higher horsepower engines.

4-pt Deck to Hull Fusion - Sylvan deck brackets have 4 points of fusion for an extended area of contact with the tube. In addition to providing increased strength and support, this reduces frame twist and racking in rough water and guards against tube fatigue.