As I mentioned in a previous post, my trailer was originally setup for a V-hull boat. I have a flat bottomed Jon boat. I would have to custom build some bunks to hold it. I wanted the bunks to allow the boat to sit as low as possible on the trailer to make loading and unloading easier. They also had to handle the elements, so I don’t have to replace them any time soon.
I found some black marine carpet at my local boat shop, 12″ wide and 12′ long, so I got two rolls. I had previously bought two 8′ treated 2″x4″s to use as temporary bunks to get the boat home, and I would use these for the final bunks as well. For length, I want the transom to sit over the cross member at the back of the trailer, so I made the back of the bunks hang over the cross member by 1″. I made the front correspond to the angle of the trailer as the framing approached the tongue. This part was easy.
The harder part now was to get the bunks to sit level, as the trailer has a ‘V’ angle to most of the cross members. I ended up notching out the wood at an angle where it sat over one of these angled members so that in the end the tops would be level to support the boat properly. The rear cross member was slightly lower than the others, so I had to had some blocks to support the bunks. I then drilled holes and countersunk them for stainless-steel bolts that would hold them securely to the trailer framing.
A bunk notched out to sit level on the trailer framing
Both notched bunks on the trailer while boat is suspended
The bottom of the bunks, showing notches and spacer blocks
The tops of the bunks showing the countersunk bolt holes
Test fitting the bunks onto the trailer
With the bunks fitting nicely, I moved on to carpeting them. I used some leftover vinyl tile adhesive on the top and sides of the bunks to help hold the carpet into place while I attached it, and hopefully help prevent it from wrinkling or coming loose later in use. Once dry, I laid the bunks upside down onto the back side of the carpet and slowly molded the sides to conform to the boards. Some creative trimming with a sharp utility knife helps it all to fit. Finally I used a row of galvanized roofing nails spaced about 4″ apart to secure one edge of the carpet to the bunks, than followed it with another row to secure the other edge. I hope to get a number of years of use before the chemicals in the wood are able to eat away the nails (the new chemicals in treated lumber will eat most metals, so use stainless steel where possible), and they should last much longer than staples would have.
The bunks covered with vinyl tile glue using an 1/8
Forming the carpet onto the bunks
One bunk completed, the other under way
Trimming around the spacer blocks was trickiest
Carpet attached, bolts in place
Bunks attached, boat lowered into place
In the end, I’m quite happy with how they turned out. They look great, fit the trailer like a glove, and are functioning perfectly.
