Every time I've mixed epoxy it looks mire like it's been whipped with an capaccino machine. Wish I could do that with my coffee! Anyhow, the air bubbles always seem to go away.

With regards to the thickener, I don't know. I can tell you that I think I used three cans of cabo-sill in making my kayak.

The honey thickness sounds rather thin. For I agree with you that unthickened epoxy is about the consistency of honey. CLC and most other instructions give it in terms of katsup, mayo, peanut butter. Or something very similar. I would think for filling seams (not filleting) you would want a consistency of at least mayo so that it doesn't sag right out. If you're filleting, I'd head more towards peanut butter thickness.