: I don't follow you, why use a fillet connecting two panels meeting at an
: angle using only glass on the interior? With rounding over that would
: leave the chines less than the thickness of the wood.

i wasn't realizing that you round the edges of the ply therefore thinning the ply edge out to almost the fillet or at least by an appreciable amount. i thought that you slightly bevelled the ply edges(or rounded the inside) so they fit sorta like a mitre.
that would of course make it hard then to glass the outside as it would have sharpish edges.

but now in retrospect, the thought i had actually makes more structural sense in that it might be better to have 1/8 inch of grp than 1/8 in of just hardened glue. but of course way more work.

when you sand down the outside of the chines, how much of the core is exposed?(by the way, i was not implying eliminating any outside glass that would normally be there, just talking about the inside and having a cloth 'fillet' instead of a glue fillet)

i guess another way would be to not bevel or round the inside edges but put the fillet on the outside between the angle separated edges to round over that. then could get a clean but rounded edge. making the inside peaky edges meet would be real hard tho'. maybe wire around a pc of 1/2in dowel for those areas and hot glue tab between - mucho worko, and not likely.