Hi,

I finished stripping my kayak about a year ago now and after a long "break" to get my business in order (good luck, but at least I have a little more time now :-) I have finally finished sanding my 1/8" North Star (a little on the heavy side of 1/8"th, forget the exact 1,000th now). And now comes the step that I (like so many others before me) have found a little intimidating. I have read about it and I think I am as ready as a "first timer" can be ... BUT still it is like "concrete day" because once the epoxy is on it's ON! I Haven't done epoxy/fiberglass yet, except on the two 25"X18" FLAT bulkheads. I've learned somethings from the "practice panels" but sure would like to check my last questions now with the experienced guys on this board !

1.) My best info is that it is ok to hand sand the hull with 120 sand paper (with the grain) prior to applying the epoxy. I am aware of the thinking that you should not sand the hull with finer that 80 grit to create enough roughness to properly bond the epoxy. But I am using System Three "clear coat" for the seal coat (and for "wetting" out the 6 oz.fiberglass cloth) and I believe that this "thin" epoxy and the "softwood" (redwood & cedar) will result in a proper bond to the wood with it sanded as fine as 120 grit. Any real reason to change to an 80 grit final sand ??? It's my last chance !

2.) After hearing so many opinions about it both ways, I'm going with the "seal coat first" method. From my limited experience the brush method of applying this coat seems good, easy and hard to screw up. The roller is faster, but it creates those bubbles we all hear about. What's the rush to use a roller when I am using a relativly slow cureing epoxy with no amine blush (even when fully cured) and since I am mixing such small batches (9oz.at a time) there is no need for the "speed" of the roller. Or am I underating the benefits of the "even" effect of the roller and this method is best for that reason. So is it best to "even" the coat with the roller and just go over with a foam brush to get rid of the bubbles. Anyone prefer using a foam brush alone? Why not just buy a good brush (to drop less bristles) and just do the seal coat that way ? I have put so much effort to get to this point, so what if I spend $20 for a good way to finally get a good, controled seal coat on? Appreciate your experiences about which method is best for the "seal coat" method.

3.) I am not clear on the facts of sanding the "seal coat" before applying the fiberglass itself. I just have the feeling that it should be sanded and from looking at my bulkhead panels the surface sure does seem "fuzzy" I read a lot and most seem to say it is ok to sand, but many warn that you should not sand too much (does this only mean too deep?). What I want to know exactly is this: Can I sand the whole hull (carefull, I know the point would be to not REMOVE the seal coat) and what is the best method for this sanding ? Is sanding with dry 120 with a farring board with the grain a good method? Or I have thought I should try steel wool on my panels. Or should this be a "wet sand" ? I have heard that sanding at this stage can (if done incorrectly) cause the finish to be uneven and haven't found a definite answer yet or the exact sanding procedure. I am going to try some different methods on my panels tomorrow and will report back on my findings. Sill I wonder if the effect on the whole hull could cause an uneven finish if it isn't done right and would appreciate having the word of someone who knows where I am.

4.) Like to get one more thing straight with you guys: Is it always best to put the "smaller" piece of fibergalss "over" the bigger ? I mean on the hull there is the 2nd piece that doubles below the water line, my informaion is that it is best to put this smaller layer "over" the "full" layer. Second there are several smaller pieces at the hull and stern to be added to reinforce these sections. If I am adding 2 or 3 of these pieces one 'over' the other, wouldn't it be best to start with the smaller and progressivly cover witha "bigger" piece so as to cover and begin to feather the edge ? Also how is it best to deal with "cut" edge of the fiberglass on the "2nd" layer ?

Looking forward to the seal coat and putting on the glass, thanks for your time.