All of those you mention but welding a highly flammable material into a sealed container is essentially making a bomb that will likely see you spread all over the roof of your bosses workshop.
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I reckon bin the 8hp and go more this way
https://uploads.tapatalk-cdn.com/201...a8454d932a.jpg
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Why a bad idea? To my non technical mind if your pontoon gets a hole (however that might happen), it will leech water into the cavity and cause a list when it fills up but if the cavity is full of polystyrene then bugger all water could enter because the the polystyrene is displacing the air in the cavity.
If a pontoon gets a hole it will likely be at the bottom,if it is at the bottom it can only fill x amount before it has compressed the air inside enough to equal the water pressure and it will not fill anymore(fill the sink and lower a beer glass upside down into it and you will see what I mean),also one is unlikely to hole a pontoon while stationary (when it could possibly fill with water and be an issue), there will be 4 separate sealed chambers so even if say one developed a crack while underway and filled while fishing at anchor while I would be pissed at my shoddy design it still wouldn't sink or even get close to sinking.
The reason I went with a pontoon design is so if swamped(short transom remember) or I have been a dick and take a greeny over the bow it will want to float upright and should be bailable/restart motor fuck off etc.
Pontoons themselves do absolutely nothing for stability until you get in a situation where there is lots of water on the inside of the boat...then they work.
The "stability" people rave about with their various pontoon hulled boats has absolutely nothing to do with the pontoons, hull shape gives(and takes away) stability.
Be OK if you never wanted any welding done on the boat ever again, crack it/scrap it.
FYI for all of you.
If you crack your alloy boat somewhere and would like it fixed DO NOT SILICON UP THE CRACK!
Just let the fucker leak untill you can get it fixed, in an emergency Kneed it or similar will do but silicon in cracks will basicly tripple the cost of any repair and the repairer will call you a cunt behind your back....so now you know ay :thumbsup:
Is bitumen tape safe?
nooo never fill pontoons
6mm bolt? why not a plastic removable bung like senator use?
open it on a hot day and get that satisfying hiss
but mostly because of dissimilar metal reaction
6mm bolts are effectively free and indestructable.
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