Even if the fumes WONT kill somebody who clearly has a reaction, how much discomfort is it fair to put then through?

While I dont like Georges manner, I have to agree with him on this one. There's more to this than meets the eye. It's possible that the MSDS is based on flawed data, or insufficient data in your son's case. Or that your son is the one in a thousand with an extreme reaction.

Would it be feasible to add ventilation such that the epoxy-room is under negative pressure, vented outside? This can be very effective with fume control. I'd even offer you a wholesale deal on a fan, Dale.

: the epoxy is probably less smelly than latex paint. if you can paint a wall
: without bothering the family, you can do a boat.

: But, keeping a window open a crack will help the ventilation a lot.

: Close off the room where you are working -- as best you can. I've just read
: of one person using plastic sheeting. That sounds like a good idea if you
: can't just close a door to the room.

: Since it is cold outside, consider opening the window a crack jsut as soon as
: you put the last drops of resin on the boat. This will not only suck the
: heated, resin-smelling air out of your house, but it will cause the room
: temperature to drop a bit, which should be considered a benefit, as it
: should reduce outgassing from the wood.

: If you are working with the windows closed, though, then you definately need
: a respirator mask, as you'll be breathing nothing but those fumes for a
: few hours -- and you don't want to do that.

: Once you start glassing plan to procede at a rapid pace so you finish the
: entire job before anyone gets fed up with you. Once the resin has started
: to harden and the boat can be taken off the forms and moved, get it out of
: the house. It will smell of plastic (that "new car" umm boat
: smell) for a while If you can move the whole thing while it is still on
: the forms, that is even better. By the time you get around to varnishing
: it the weather should be better.

: PGJ