Welcome to Bennington.
Our tour begins where flat aluminum stock is pre-rolled into cylindrical pontoon chambers. The material is available in multiple thicknesses, with the selected gauge depending on the boat’s performance package. Two-tube, triple-tube, and high-performance elliptical packages use thicker gauges to support larger motors. Once formed, each chamber moves to robotic welding, where the top seam is stitch welded with precise, consistent penetration to ensure strength and durability.
After the top seam is complete, each chamber receives a barcode identifying how it will be assembled into a specific tube for a specific boat. Baffles are then welded into each chamber to add structural strength and maintain integrity in rough water. The nose cone is installed to enhance performance, allowing the boat to cut through waves smoothly for a better ride when towing skiers or tubers.
At Bennington, craftsmanship runs deep. Many employees are second- and third-generation team members who understand what Bennington quality stands for. Each pontoon features a solid extruded keel that protects the tube during beaching, storage, and transport while also improving tracking, steering, and maneuverability at both high and low speeds. Full-length keels run from the nose cone to just past the end cap, adding strength to every pontoon.
Each chamber includes a coupling that allows for individual pressure testing. Every chamber is tested two to three times to ensure there are no leaks before moving to final assembly. To attach the deck to the tubes, saddle brackets—also known as M brackets—are welded into place. Their wide base distributes impact evenly across the tube, preventing deformation in rough water. Precision jigs ensure each bracket is welded to exact specifications, allowing for accurate replacements years down the road if needed.
A 10-kilowatt laser cutter precisely shapes components at high speeds, allowing Bennington to control quality and lead times in-house. Precision bending machines ensure every part meets exact specifications. The center tube forms the transom where the motor is mounted, and its heavy-duty construction and high-penetration welds ensure reliable performance in demanding conditions. Below, performance foils help the boat maintain control through turns, improving handling for skiing, tubing, and high-speed cruising.
In the framing department, all tubes come together to form the boat’s structure. Reinforcement runs from stern to bow, adding strength throughout the frame as storage areas for fuel and gear begin to take shape. Where crossmembers do not span the full width, thicker gauge aluminum is used for added reinforcement. In some areas, dual C-channel beams are installed back-to-back with foam gasket tape between them to deliver a quieter, smoother ride and prevent water intrusion. All framework is secured with 3/8-inch stainless steel bolts to ensure long-term durability and structural integrity, supporting a lifetime structural warranty.
Bennington’s exclusive bowrider pontoon features a forward foot pocket that lowers the passenger’s center of gravity for a smoother ride. The design delivers maneuverability similar to a speedboat while maintaining the stability expected from a Bennington pontoon. Reinforcement extends from stern through bow to protect the frame during docking.
Next is the decking process. Gasket tape is applied along the full length of each crossmember to prevent moisture intrusion and reduce noise. The deck uses 3/4-inch, 7-ply pressure-treated wood for a quieter ride and superior holding power. It is through-bolted with stainless steel hardware to prevent flexing and keep the structure tight—a proven method used for over 25 years. Before vinyl flooring is installed, every deck is sanded and leveled to eliminate seams and high spots, ensuring a smooth finished surface.
In the rail department, anodized rails are produced in silver or blackout finishes. Each rail is marked with a production number and build date. Foam gasket tape is installed behind every panel to minimize vibration and eliminate rattling on the water. Rails are slightly elevated to allow water runoff and airflow, helping the deck dry efficiently.
Furniture installation follows, with cushions built using five foam densities for improved comfort and durability. Quality is built into every step of the Bennington process, and any team member can flag an issue to ensure it is addressed. Final inspections include detailed production photos documenting the boat’s condition before shipping.
One of the final steps is the wave-taming system. Aluminum panels are installed along the inside of the tubes and beneath the crossmembers, allowing water to flow smoothly under the boat with minimal resistance. This design functions much like an aircraft wing, delivering a smooth, efficient ride. Wave-taming is standard on all triple-tube pontoons and is also available on select twin-tube configurations for choppier waters.
Thank you for taking the time to experience the Bennington process. We’re as proud of how we build our boats as we are of the boats themselves.
