: I've got about 1/8 to 1/4 inch of epoxy/glass on each seam, and some "less than nice" feathered edges (i.e., a few hard edges of epoxy)

Ed,

I'd strongly recommend a sanding session before stitching the panels together. You want to make sure that the edges of the panels are not made uneven by epoxy seepage, and I'd think that trying to stitch the sections together with those thick expoxy sections would affect the flex of the panels as well. SAnding now, both feathering the edges and the overall thickness down to perhaps just above the seam tape will be worthwhile. I stopped just as soon as I saw a hint of the tape weave showing through on the Arctic Tern I'm building. It made for a very smooth finish to lay the hull cloth over. If you haven't got a random orbital sander yet...get one now! Good luck, Chuck