US Patent 7739975 Roll formed pontoon and method of manufacture

A method for making a pontoon for a pontoon boat and the pontoon made from the method. The method having an initial step of providing a sheet metal strip that has a width and a length. The strip is then formed longitudinally through successive rollers to provide a central portion having a closed cross section in which the lateral edges of the strip meet. After this stage of the process, end caps are formed at each end of the central portion. Typically, one of the end caps is a nose cone that is pointed and cuts the water as the boat moves forward. The end caps may be formed independently and separately of the strip or may be formed from material at the end of the formed strip.