Hi Todd,

For applying the fillet I like to use a spreader made from 1/32" thick plastic.

The advantage of the plastic is that it flexes to suit the contours of the panels pushing the thickened epoxy along forming a smooth well transitioned fillet while scrapping off the excess. A bit of experimenting will show you what angle to use and how much pressure is needed. With a bit of practice you could fillet the 3 seams of a Chesapeake 17 in less that 15 minutes.

Mix only enough filled epoxy for one seam to start. I apply blobs of epoxy all along the seams [you want it out of the mixing container quickly so it doesn't heat up and start to set] then make a first pass with the spreader to distribute it. The second [and typically final] pass I make from the ends to the center of the kayak.

With the shape of the spreader you should end up with about 1/4" deep of epoxy in the seam corners feathered to nothing - I.E. the panels are scraped of epoxy beyond the feathering. Hard to describe... my joints are "hollowed" and the feathering is 3/4 to 1" on either side of the seam. You probably have pictures to refer to.

Don't be overly fussy about the appearance because you will be applying tape to the joint anyway. The idea is to get enough of a fillet to cover the joint and feather on to the panels without adding too much. You will probably scrape off 3/4 of the epoxy that you put on. By the time you get to the last joint you will be able to judge how much epoxy to mix/apply.

I use two sizes of these applicators, a 2" wide for panel seam fillets and a 1" for filleting bulkheads. The plastic should be quite stiff - about the stiffness of "shirt cardboard".

Don't have a picture to show you so I hope my description is clear enough. The dimensions are approximate to give you a starting point.

For the panel spreader, cut a rectangle of plastic 3 x 7 inches, at one end - trim off a 3" x 1/2" triangle from each of the 7" sides narrowing the 3" to 2" wide. Trim the resulting 2" width to a form half a circle.

For the bulkhead spreader, cut a rectangle of plastic 2 x 7 inches, at one end - trim off a 2" x 1/2" triangle from each of the 7" sides narrowing the 2" to 1" wide. Trim the resulting 1" width to a form half a circle.

Hope this helps, enjoy your building.

Hank

P.S. don't forget to wear gloves when working with the epoxy ;-)