From my experience, filleting the inside sheer seams first is a good approach and slightly preferable. The first Pygmy I built was the Arctic Tern, one of Pygmy's more recent designs, and more recently written manuals. The basic construction is the same as an Osprey. The manual, however, calls for gluing the deck on, filleting the inside sheer seam, then rounding the sheer seams and gluing the deck on. After I built the Tern, I built an Osprey Double, and the directions were, like yours, to round the sheers, glass the deck, then do the inside seams. I called Pygmy and asked if there was a reason for that. I was told no, that it can be done either way, but that they now lean towards doing the inside seam first as reinforcement. They just haven't been able to redo their Osprey manuals (although evidently the task is underway). So I did the Osprey in the same order as the Tern, and it went well. If it were me, I'd do it as you propose. If you have any lingering doubts, I think a call to Pygmy would put them to rest. Good luck (gluing the inside seam is probably my least favorite step of everything on a Pygmy!).

: The directions that came with the kit talk about glueing the deck on
: something like this: 1) tape the deck in place
: 2) run a bead of epoxy around the outside of the boat on both sides where the
: hull and the deck meet
: 3) Sand the deck and round the deck/hull edge
: 4) Glass the deck
: 5) Run a fillet of epoxy on the inside of the deck/hull seam.

: This raises a number of questions -
: 1) Taping the deck in place was an exercise in patience - and clamps and
: straps - to get it aligned perfectly. The joint between the beveled edges
: of the deck and hull is so thin that it seems that very little epoxy will
: actually find it's way in there. Will this really hold when I take off the
: tape and clamps?
: 2) The directions say to sand next - well, if I sand and round the edge of
: the deck/hull joint I'm pretty sure that's going to sand off all the epoxy
: I put on on the prior step and boing, off pops the deck...
: 3) Doesn't it make more sense to epoxy the outside of the deck/hull joint,
: let that dry. Then remove the clamps (but leave the tape I'm thinking)
: Then run the fillet on the inside of the deck/hull joint, let that dry.
: Remove the tape. And finally, sand the edges and glass the top of the
: deck? Or am I missing something???

: Anyway, I could greatly use the help. Thanks in advance again for your
: responses...

: Brion