Wooden Facelift For Jon Boats: A Simple Guide

Putting a wooden front on your Jon boat is a time-consuming task, but it will be very rewarding once you're done. The easiest and fastest way to build a Jon boat is to make it straight and square from front to back. The first step is to create the floor or bottom of the boat, and then set the bottom rails and first cleat board. Next, glue and screw the pieces together. After that, you can work on the sides and seats. Finally, finish with any customisations and a thorough clean.

Creating the floor or bottom

The first step in building a Jon boat is to create the floor or bottom. This will serve as the base for the rest of the boat, so it's important to get it right. Here's a detailed guide on how to do it:

Start by placing the first plywood bottom or floor on the ground. Make sure it's been trimmed to the desired size, such as 48" x 42". The front boat's offset should be measured properly and should be at least 3 inches wide in the front.

Next, measure 24 inches from the front offset and place a 1-inch winch offset at that location. Use a flexible ruler to draw an offset line connecting these two points. This line will guide your cuts.

Using an electric hand saw or another suitable tool, begin cutting the wood along the path you've sketched. Mark the positions for the rails on both sides, from the front to the first piece of plywood. A 3/4-inch offset is recommended, but minor adjustments can be made if needed.

Now, it's time to set the bottom rails and the first cleat board. Secure the rails in position using a clamp and the lines you've drawn as a guide. The rails should be placed on the edge but close to the line on the interior side. Use screws to secure them in place, spacing them about 6 to 8 inches apart.

After the rails are secured, retrace their lengths with a pencil to mark their positions clearly. This will be important for the next steps.

Connecting the Plywood Sections

The next step is to attach the second piece of plywood to the rear, ensuring it is the same size as the first. Pay attention to the overhang you created with the first plywood; the second piece should have the same 3/4 overhang.

On the second piece of plywood, mark the positions for the rails. The rails should allow for a 3/4 exposure where the front board for the bow will be placed later. Install screws in the second plywood in the same way you did for the first.

Now, you can start working on the cleat board that connects the two pieces of plywood. The length of the cleat board should be the same as the distance between the rails, and its width should be enough to cover both plywood sections. Use screws to attach the two pieces of plywood together through the cleat board.

Once the cleat board is in place, you can unscrew and remove the rails. Wipe the areas where the rails were placed with a clean, damp cloth to remove any dust or dirt. Dampening the gaps will also improve the glue's adhesion to the wood.

Gluing and Setting the Arch

In this step, you'll be applying glue to the joints. Make sure the glue runs uninterrupted and doesn't stray over your marking lines. This will ensure a watertight seal between the rails and the plywood floor.

Now, replace the rails, placing them back into the same screw holes as before. It's helpful to have an assistant for this step. As you install the rails, wipe away any excess glue that leaks out.

Do the same for the cleat board, wiping away any excess glue. To create an arch in the front of the boat, place a wooden piece at least 4 inches thick under the front. This will hold the arch in place while the glue dries for at least 8 hours.

To mark the location for the second cleat board, insert a piece of wood with the same thickness as the first cleat board. Gently weigh down the wood to stimulate the arching.

With these steps completed, you'll have created a sturdy floor or bottom for your Jon boat. The next step will be to work on the sides and seats, which will be attached to this base.

Setting the bottom rails and first cleat board

Securing the Bottom Rails:

• Place the first plywood bottom or floor on a flat surface, ensuring it is trimmed to the required size (e.g. 48" x 42").
• Measure and mark the front boat's offset, which should be at least 3 inches wide.
• Measure 24 inches from the front offset and mark the location for a 1-inch winch offset. Draw an offset line using a flexible ruler.
• Cut the wood along the marked path using an electric hand saw or similar tool.
• Mark the positions for the bottom rails on both sides, extending from the front to the initial piece of plywood. A 3/4-inch offset is recommended but can be adjusted slightly.
• Use a clamp to secure the bottom rails in position along the marked lines. Position the rails on the interior edge, close to the line.
• Screw the rails in place, spacing the screws 6 to 8 inches apart. These screw positions will also indicate where the glue will be applied later.
• Retrace the lengths of the rails with a pencil to clearly mark their position.

Preparing the First Cleat Board:

• Connect the second plywood piece to the rear, ensuring it is the same size as the first. Maintain the 3/4 overhang created with the first plywood.
• Draw the rails on the second piece of plywood, allowing for a 3/4 exposure where the front board for the bow will be placed.
• Screw the second plywood piece in place, following the same process as the first.
• Measure and cut the first cleat board to match the distance between the rails. Its breadth should cover both plywood pieces.
• Attach the two plywood pieces together by screwing through the cleat board.
• Unscrew the bottom rails and clean the screw holes and surrounding areas with a damp cloth to remove any dust or dirt. Dampening the gaps will improve the glue's adherence to the wood.
• Re-screw the bottom rails, ensuring they are aligned with the previous screw holes. Have an assistant help with this step as it can be tricky.
• Wipe away any excess glue that leaks out during this process.
• Allow the glue to dry for at least 8 hours.

This process is crucial in ensuring a strong and secure connection between the two plywood pieces that form the hull of your Jon boat. Taking your time and carefully following these steps will result in a sturdy and seaworthy vessel.

Gluing and screwing

Prepare the Wooden Parts:

Before you start gluing and screwing, ensure that all the wooden parts are cut to the exact size and shape you need. This includes the plywood base, rails, cleat boards, and any other components you are using. Mark the areas where the rails and cleat boards will be attached with a pencil.

Gather Your Tools and Materials:

Make sure you have all the necessary tools and materials ready before you begin. For gluing and screwing, you will need:

• Wood glue (Gorilla Glue is recommended)
• Screws
• Electric screwdriver
• Clamp
• Clean wet cloth

Apply the Glue:

When you are ready to start gluing, use a steady hand to apply a continuous bead of glue along the marked areas. Ensure the glue does not stray over your highlighting lines. This step is crucial to creating a watertight seal between the wooden parts.

Attach the Rails:

With the glue in place, it's time to reattach the rails. Ask someone to help you align the rails with the screw holes you drilled previously. As you install the rails, wipe away any excess glue that leaks out. The rails should be firmly attached and sealed to the plywood floor.

Secure the Cleat Board:

Follow a similar process for the cleat board. Place a wooden piece at least 4 inches thick under the front of the boat to create an arch. This will need to stay in place for at least 8 hours while the glue dries. Mark the position for the second cleat board by inserting a piece of wood of the same thickness. Slightly weigh down the wood to encourage the arching.

Check for Leaks:

Before moving on to the next step, carefully inspect your work and ensure there are no water leaks between the rails and the plywood floor. This is crucial to ensure the safety and durability of your Jon boat.

Constructing the seats and sides

First, attach the second cleat to the back of the boat. Once the second cleat is in place, you can start putting the sides on the offsets that you have noted at the edges. Apply the adhesive, then put the sides in place with a clamp. Remove any extra glue that foams up.

Now it's time to make the seats. Stick the upright boards that have been measured before to the sides of the backmost section of the boat. You can now paste the transom to the boards. It should span the whole width of the two sides. The same goes for the bow and prow. Before attaching and putting the transom in place, dry-fit it to make sure it fits well and make any required modifications.

Place two cleat boards horizontally between the two other vertical cleats you established before. After that, you may install the plywood for the seat. Continue working on the remaining seats using the same method of connection: glue, then screw. Turn the boat over and begin installing four oak (recommended) rails to protect the boat from abrasions caused by sharp pebbles or other debris encountered while boating.

Customising, finishing and cleaning

Customising

• Handles can be attached to the front and back of your Jon boat to improve safety and stability when riding or boarding.
• You can make your own SeaDeck with EVA Marine Foam and glue it to your Jon Boat floors.
• You can add vinyl stickers to your Jon Boat.

Finishing

• Sand and clean your Jon Boat to remove any leftover glue foam or dust.
• Apply a thin layer of wax, fibreglass protectant, or another product recommended by the manufacturer to protect the finish of your boat's hull.

Cleaning

Hull

• Use a cleaning agent that will remove stubborn stains without damaging the paint or gel coat.
• Baking soda is one of the best all-around cleaners for your hull. It is safe for almost any surface, easy to use, and environmentally safe.
• Mix a cup of baking soda with any commercial hull cleaning solution for a more effective clean.
• For hard-to-remove stains, make a paste with a few tablespoons of baking soda and a small amount of water, then scrub.
• Rinse first with clean water to remove any debris, loose dirt, etc. before scrubbing.
• Apply a cleaning solution using a clean, soft brush or cloth, scrubbing lightly to loosen remaining dirt and debris.
• Rinse and dry.

Windows

• Most Jon boat windows are made from Plexiglass or Lexan, not glass, so commercial glass cleaners should be avoided as they can cause damage over time.
• A simple, cheap solution for cleaning the windows is to mix water, rubbing alcohol, and ammonia (45%, 45%, 10%). Apply with a clean cloth and let dry.
• Rinse with plenty of fresh water to remove dust, grit, and dirt, which can scratch the surface.
• Dry, either by air or with a clean cloth.
• Apply a specially formulated restorer to protect the windows.

Vinyl Seats

• Wipe down the vinyl surfaces to remove surface debris.
• Apply a baking soda paste to remove stains or mildew spots.
• Scrub with a gentle household dish detergent and water solution.
• Rinse with clean water.
• Apply a thin coat of vinyl protector to prevent sun damage and minimise staining.

Trim

• Most Jon boat trim is made from aluminium, so be sure to scrub or wipe with the grain to prevent damage.
• Avoid using ammonia on aluminium as it will cause pitting.
• Most of the metal can be cleaned with a damp cloth and a mild laundry detergent.
• For tough stains or oxidised trim, polish the area with the shiny side of everyday aluminium foil.
• You can reduce cleaning time by using an all-in-one cleaner/polisher/protectant, such as Boatlife's Aluminium Cleaner.

Frequently asked questions