How to Make a Pontoon Boat Cover

X-HT-200647

If you need a new cover for mooring, trailering or storing your pontoon boat, why not make one yourself? For only a little more than the cost of an average pre-made cover you could sew your own perfectly fitted, custom cover that will last for much longer. In our "How to Make a Pontoon Boat Cover" video tutorial, we will walk you step-by-step through the process of sewing your own custom cover.
Video Chapters:
  • Measuring & Sewing Fabric Panels – 0:33 min.
  • Installing Boat Vents – 6:22 min.
  • Patterning with Darts – 11:43 min.
  • Creating Slit Openings & Marking Fabric – 21:05 min.
  • Patterning Fabric on a Flat Surface – 27:48 min.
  • Adding Stern Facing – 34:53 min.
  • Sewing Darts, Chafe Patches & Hems – 39:07 min.
  • Adding Triangular Panels – 49:09 min.
  • Finishing Slit Openings – 54:40 min.
  • Installing Snaps – 59:10 min.
  • Materials List – 1:03:00 min.
Materials List:
  • SureRite® Forest Green 60" Fabric – #125608
  • Seamstick 3/8" Basting Tape for Canvas – #129
  • PremoBond® Tex 90 (V-92) Black UV Bonded Polyester Thread 4 oz. – #123338
  • Boat Vent II™ Black – #105135
  • Cam-Lock Support Poles - Snap & Swedge Tip – #105131
  • Black Polypropylene Webbing – #PLLWBK
  • Sunbrella® Acrylic Bias Binding Tape Black – #124900
  • Nylon Hook Black – #100255
  • Nylon Loop Black – #100256
  • SnapRite® Fastener Cloth-to-Surface Set 3/8" Screw (Nickel-Plated Brass) – #104911
  • Filament Strapping Tape 3/4" – #5643
Tools List:
  • Spring Clamp – #50211
  • Soapstone Fabric Marking Pencil White – #102766
  • Deluxe 5-1/2" Magnetic Sewing Guide – #103597
  • Sailrite® Ultrafeed® LS Walking Foot Sewing Machine – #311502
  • Tape Measure, Straightedge, Scissors, Ladder, Office Clips
How to Make a Pontoon Boat Cover Video 2

For our pontoon cover, we chose to use SureRite® Fabric. SureRite is a solution-dyed polyester with a urethane coating on the underside to increase water and mildew resistance and to add stability. It is a great cover choice for boats in the Midwest or other more temperate climates. If you live in the tropics, where the sun is stronger, you might want to use a Sunbrella® Marine Grade fabric, which will offer even better UV resistance.

This style of pontoon cover fastens to the boat via snaps around the perimeter and features a venting system. The cover is tented to prevent water pooling using Cam-Lock Support Poles. In this video, you will learn how to determine the amount of material needed, install boat vents, create darts, add chafe protection, and install snaps and support poles.

Have you ever made your own boat cover? Share your tips and advice in the comments!

Materials List:

SureRite Forest Green 60" Fabric

#125608

SureRite® Forest Green 60" Fabric

Seamstick 3/8" Basting Tape for Canvas (50 yds.)

#129

Seamstick 3/8" Basting Tape for Canvas (50 yds.)

PremoBond Tex 90 (V-92) Black UV Bonded Polyester Thread 4 oz. (1,350 yds.)

#123338

PremoBond® Tex 90 (V-92) Black UV Bonded Polyester Thread 4 oz. (1,350 yds.)

Boat Vent II Black

#105135

Boat Vent II™ Black

Cam-Lock Support Poles - Snap & Swedge Tip

#105131

Cam-Lock Support Poles - Snap & Swedge Tip

Black Polypropylene Webbing

#PPLWBK

Black Polypropylene Webbing

Sunbrella Acrylic Bias Binding Tape Black

#124900

Sunbrella® Acrylic Bias Binding Tape Black

Nylon Hook Black

#100255

Nylon Hook Black

Nylon Loop Black

#100256

Nylon Loop Black

SnapRite Fastener Cloth-to-Surface Set 3/8" Screw (Nickel-Plated Brass)

#104911

SnapRite® Fastener Cloth-to-Surface Set 3/8" Screw (Nickel-Plated Brass)

Filament Strapping Tape 3/4" (60 yds.)

#5643

Filament Strapping Tape 3/4" (60 yds.)

Tools List:

Spring Clamp

#50211

Spring Clamp

Soapstone Fabric Marking Pencil White

#102766

Soapstone Fabric Marking Pencil White

Deluxe 5-1/2" Magnetic Sewing Guide

#103597

Deluxe 5-1/2" Magnetic Sewing Guide

Sailrite Ultrafeed LS Walking Foot Sewing Machine (110V)

#311502

Sailrite® Ultrafeed® LS Walking Foot Sewing Machine (110V)

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