How to Make a Pontoon Boat Cover

Item # 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.

DIY Pontoon Boat Cover

For our pontoon cover, we chose to use Sur Last® Fabric. Sur Last is a solution-dyed polyester with a urethane coating on the underside to increase water and mildew resistance and to add stability. Sur Last 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.

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:

  • Sur Last®, Top Notch® 9 or Sunbrella® Fabric (we used Sur Last in Forest Green #386000)
  • Seamstick 3/8" Basting Tape (#129)
  • V-92 or Tenara Thread
  • Boat Vent II #105135
  • Cam-Lock Support Poles #105131
  • 1" Polypropylene Webbing (we used Black #100080)
  • 1" Sunbrella® Acrylic Bias Binding (we used Black #12400)
  • 2" Nylon Hook (#100255) & Loop (#100256) Velcro
  • Cloth-to-Surface Snap Fasteners #104911
  • 3M™ Filament Strapping Tape #5643

Tools List:

  • Pony Clamps #50211
  • Cam-Lock Support Poles #105131
  • Soapstone Fabric Marking Pencil White #102766
  • Deluxe Magnetic Sewing Guide #103597
  • Sewing Machine
  • Tape measure
  • Straight edge
  • Scissors
  • Ladder
  • Office clips

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