As a first time builder using those very instructions and techniques, my Ches.17lt came out 42lbs rigged up. I was careful in squeeging epoxy out on glassing, and sanding between coats. Fillets were as per the book. Used 4mm okoume. Third boat a Ches 16 came out less than 40 lbs. rigged.

: ChrisK initial instructions for the CapeCharles/Patuxents showed pictures of
: fillets as wide as the 3" tape. I suspect the progression of
: oversized fillets started from the shallow angle in the Yare/Seven and
: continued into the DRAWINGS of the hard chined Cape Charles where two
: layers of 3" tape was in the instructions. Using the same drawing in
: later instruction a first time builder is more likely to make huge fillets
: unless their dimensions were specified otherwise,,I sure did when making
: the Patuxent for the very first time. The CLC demo boats went through a
: similar evolution of huge goopy fillets to narrower and narrower ones as
: someone new built the next demo boat. A first time builder going from
: instructional drawings showing fillets as wide as the 3" tape is more
: likely than not to continue the practice elsewhere,,bulkheads,,then things
: can get really out there "if a bulkhead needs a fillet why not the
: deck beams,,or sheerclamps,,,or ,,or..." and poof,,55lb s&g kayak
: with 4oz deck glass and no glass on bottom panels in the compartments with
: huge endpours due to the sheerclamp set-backs at the ends.

:
: http://www.clcboats.com/shoptips/shoptips_fillets.php/cart_id=46f356086cf464bd0f0b1d3f453150cc/