If you are planing on coating the wood with epoxy before you even start to stitch I believe you will regret it. The wood will become extremely stiff, and all subsequent epoxy coats will be a mechanical bond only to that base layer. Remember, if a second coat of epoxy is laid on quickly before the first has fully cured, they will chemically meld. If you let the first fully cure, the second cures seperately, and it is only mechanically bonded by the roughness of the first coats surface.

I would suggest going as per the instructions, which is to cut it and stitch it before any epoxy touches the wood whatsoever. Do the filleting, cut the wires, and glass cloth it.

Luan varies tremendously in quality and type. I've found the Home Depot near me to have very good luan (thickest outer skins of any I've found, consistent cores, woven reenforcement mesh under both skins). Very strong and cheap. I know a number of people on the web and personally now who have built quite large boats using luan. Boats that have lasted many years. I would not be afraid of it or ashamed of it.

> My son and I are sending off for the cape charles kayak plans
> fron clc. We can only find 1/8" luan plywood at our local builder
> supply store. We want to keep the cost down, but don't want to make
> a poor plywood choice and end up with a boat that will not last. Since
> we plan to coat all sheets with epoxy before we start to "stitch
> and glue" and will use glass cloth over the hull after we construct,
> do we need to use the more expensive marine plywood? Thanks for any
> input.