My girlfriend got a dirt cheap deal on a 28' pontoon, Merc 65hp motor, and trailer. I checked it out for her and have already got the motor running great for less than $50. (I'm an ex-marine (Mercruiser certified)mechanic). The trailer is in good condition and I towed the rig 40 miles home. The pontoons however are going to need some work and have a couple of holes from damage at the sterns. Welding aluminum is no problem but I find now that the right (starboard) pontoon is heavier than the left (port) and they are filled with the white styrofoam used in cheap coolers and coffee cups which is breaking down into the little white balls. This foam is saturated and therefore adding the extra weight. I know that I may have to cut holes in the sides of the pontoons to remove the foam and thinking about using a 4" hole saw at the top outside. <br />The pontoons are of the canoe type with the flat top deck riveted on and the cross members riveted on both inside and outside. I would hate to have to remove the entire decking, cross members, and rivets to remove the pontoon tops. I have no idea of the location of any baffles except the forward bow. Someone suggested melting the foam with gasoline, I nominated him for the Darwin Award for this year. Is there another non-flamable way to remove the foam? I'm thinking along the lines of scooping out as much possible and then using a pressure washer to blast out the rest which should flow out of the 4" hole. Also when I get ready to put it all back together I would like to use an expandable foam in the pontoons before welding the 4" cut-outs back in. I want to keep the level of the foam lower than the weld points. How much pressure can this foam exert in a confined area? Which would be the best type to use?<br />Should I get a new girlfriend?<br />Thanks <br />Capt Ron
