I have found that the best way to save on epoxy is to be anal about its use. In my s&g boats, I use only about 1/2 to 2/3 the amount of epoxy that is normally included in kits. I have heard of builders having to buy extra epoxy above what's included in the kits. Keep your fillets small and mix epoxy in small batches to eliminate waste. One trick I use is to put a small cardboard dam in the bow and stern as soon as the hull is stitched up. Then, each time I mix epoxy, the excess (mixed with sufficient wood flour) goes into the dam for an endpour; thus no waste. Using lighter glass will reduce epoxy use at the expense of some stiffness but I always use 6 oz. and still manage build a light and strong boat with minimal epoxy. My boats usually weigh about the same as the kit manufacturers claim, so if your's is overweight, it's probably got too much epoxy in it.

George F. Johnson