Hey Dave, I use my kayaks on the NS of LS, and here is what I've used on them:

- Outside: 6 ounce
- Football: extra 6 ounce
- Inside: 6 ounce
- Inside extra: 6 ounce under seat and feet, 6 ounce in front of the cockpit (rescue patch)
- Stems: 24 to 30 ounces total

The stems hold up fine, but I did put a gouge in the bottom of my last kayak to the wood after landing on a rock, then launching from that same rock by getting in the kayak on the rock between the waves and waiting for a larger set to put enough water under me to launch. The next set was smaller about 1.5 to 2 feet and didn't put enough water under me, so I ended up sliding pretty hard on the rock. Otherwise, I didn't have any problems landing and launching from the rocky coast.

You can get away with 38", but you may save some money if you go with 60".

: 2) In the instructions that came with the plans, it said to put the football
: and stem pieces under the outer layer, while this method seems to be a
: little less work and less mess, does it leave an outline that shows
: through the outer layer and if so will fill coats and a little sanding
: clear that up?

I've always done the opposite and feathered the glass.

: 3) Has anyone done this with 4 oz under the 6 oz outer layer? Is there much
: durability that I sacrificing over weight savings?

If you can get some 4 ounce tight weave, you may save weight and gain strength.

: 5) can I use 4 oz on the inside and outside of the deck?

Yep. Think about adding a rescue patch for the deck and a patch behind the cockpit to sit on.

: I am using 3/16" strips and its alot thinner than that in some areas,
: like probably 1/8" so I want to avoid as much oil canning as
: possible.

You shouldn't see any oil canning even with 1/8" strips.