: I'm going to loft the station forms on some particle board this weekend...

This is a stitch and glue design. You shouldn't need the station forms at all if the panel layouts are correct. And if they are not correct, then they won't fit over the station forms anyhow.

For alignment purposes why not just loft and cut out the middle form and a form about 3 feet from each end. Mounting and aligning just these three forms should give you some excellent reference points, and speed you on the way to construction of your boat.

: I've only come across three build logs for this (including Nick's), but I
: know more have been built. I lofted out a 1/10 scale model of all the
: forms and panels (but haven't cut them out yet) and didn't notice anything
: weird.

Measure along the outer edges of the panels. Those which are adjacent should be the same length, so when they are joined the parts start and end evenly.
Sometimes computer generated plans do not take into account the thickness of the materials, so the numbers they kick out are for the interior seam lines. In these cases you need to cut the materials a bit oversized, and bevel the inner edges so that the length along the inner edge of the bevel matches the plans. At other times the lines are drawn for the outer edges of the material, andyou need to bevel the inner edges so you can pull the part together, with the outer edges meeting smoothly. And sometimes you don;t know what's going on, so you round over the edges of the parts you cut, and paly with the wire ties to get things aligned--and somehow it all works out OK.

: Seems like some have had trouble with the deck and side panel
: meeting near the bow but they all seem to write it off as build errors.

As I recall, at one time there were some problems with typos, and Nick had an errata list. I don't know if he has since redone the original plans to include the corrections, or if you need to look for that corrected data.

Good luck with your project. Fromw what I've read from those who have built this, they really like the design.

PGJ