Cypress Cay Pontoons Construction Process

At Cypress Cay we are dedicated to the use of premium parts and quality manufacturing practices to build the best possible boat, including acid-washed pontoon tubes and the power of Mercury propulsion. By maximizing the efficiency and maintaining uncompromising standards within the plant, Cypress Cay creates innovative and luxurious pontoons that are built for life - see Cypress Cay Warranty.

*The below construction process applies only to the Cancun, Cayman, Cozumel, Cabana and Angler. Seabreeze models use a slightly modified construction process. See your dealer for details.

Tubes

Cypress Cay construction starts with 5052 marine grade aluminum alloy sheet that is hard and thick enough to resist surface damage, but not too rigid that it will fracture. Tubes are assembled in-house and are 25" in diameter on all models.
Cypress Cay utilizes more sections than most competitors to provide more watertight compartments. Every tube has multiple sealed sections, so you can get safely home even in the rare event of a puncture.
Every tube also has a full length keel that provides a full 3/8" of impact protection, as well as keeping the tube and boat running straight and true.
Cypress Cay uses the Torsion Reduction System when attaching the tubes to the deck. Every tube uses a full length mounting bracket on the outside of the tube and spaced brackets on the inside that together provide a structure that will absorb and distribute the forces created by hard running and rough water, resulting in a smooth, reliable ride.
Tubes and cross members are squared to assure that the tubes are parallel to each other and that the structure is square to the tubes. Then the tubes are attached to the cross members with 3/8" carriage bolts and self-locking flange nuts.

Decking and Wiring

There is a full C-channel at the front and rear of the boat to provide support for bow and rear rub rails in the event of contact at the dock. Many competitors do not provide this kind of support and simply place an unsupported rubrail at both ends of the boat.
Decking is 7-ply, high tensile strength, with tongue and groove joint. Decking carries a lifetime warranty against warp, rot and delamination.
Through the deck, water intrusion is controlled by utilizing a three-step design. Butyl rubber tape is applied to every cross member where there is a deck joint, polyurethane sealant is applied to the groove of the decking material, and then the tongue is inserted into the groove providing a mechanical seal that will not leak.
The deck is attached to the the cross members using specially-designed tek screws which provide for a solid joint.
A full wrap-around rubrail system is utilized with vinyl inserts for further protection against collision. At Cypress Cay, we never use corner caps because they can be easily torn off. Our heavy duty cleats are attached to the crossmembers to ensure they will not be torn off, but will stay locked in place.
All wiring is properly supported and protected by grommets by running through the cross members. All visible wire is wrapped with a protective cover to ensure safety and integrity of the wiring.

Carpet and Flooring

All deck joints are sanded and urethane sealed and all divots created by the fastener heads are filled and sealed. This prevents lines and pock marks from showing through the carpet in the future. Many other manufacturers do not take these steps to assure satisfation and appearance after the carpet has gotten traffic.
Carpet is applied utilzing an environmentally and operator friendly water-based adhesive. All carpeting is made of marine-grade polyester fiber that is woven to Cypress Cay designs with bi-level patterns. All carpet has a rubber coating applied to the back side for higher durability and water resistance.
Thick and durable flooring alternatives to carpet are available including non-slip vinyl flooring that offers a great option for fishing and high traffic areas such as the rear of the boat.

Fence Fabrication

All fence paneling is carefully painted on both sides using automotive-grade alkyd enamels. Many competitors only paint one side of the paneling.
Cypress Cay paneling is processed through rollers to add an "imperial crimp" which adds rigidity to the fence. Many competitors utilize smooth panels which are not so forgiving and tend to exaggerate the look of blemishes.
The fence panel is mounted into the welded rail sections utilizing foam tape at any place where the panel will contact the support structure. This extra step reduces or eliminates annoying fence rattling when running at higher speeds or through rough waters.
All custom designed graphics are specified with "hi-tack" adhesive systems that resist delaminating and peeling in environmental extremes, resulting in optimal appearance for years to come. We enhance our application process with a roller device that applies heat and pressure to the graphics to maximize adhesion.

High Quality Materials

Seat upholstery features a soft, durable vinyl protected with the power of PreFixx which keeps the vinyl easy to clean, usually with simple soap and water, and resistant to stains and abrasion. Because PreFixx is built into the fabric, rather than a top coat like many competitors use, your vinyl will look good as new after years of cleaning.
Built sturdy to last long, all seat bases are roto-cast, designed specifically for durability, convenience and style.
Underneath almost every seat cushion is ample storage space, perfect for all the towels, shoes, clothing, books, snacks and water toys you might bring with you for a day on the water.
All Canvas covers and tops are made for a perfect fit every time. Covers are made from solution dyed, polyester which allows them to be light weight and provides for a cover that protects the boat from the elements, but still breathes to resist mildew.
Bimini tops are designed with an exclusive "quick release" system which allows the top to be opened and locked into position in a matter of seconds. Our tops are designed to virtually eliminate rattling, even at higher speeds and rough water conditions.

For more information regarding construction or to see a Cypress Cay pontoon in person, visit your nearest dealer today.