: . . . was just wondering if any of you doorskin users has a technique
: for strengthening voids. I thought about drilling holes along the inside
: and filling it with glue/epoxy and then gluing a thin verneer over the
: gap. Either way it looks like I need to find some marine plywood for mine.

Fill them with epoxy. You don't need to drill any holes, in fact drilling holes would just let the epoxy leak out.

If you cna see a void it is because the void is exposed on the cut edge. Tip the pane on its side and drip epoxy into the open, exposed, hole. You can do this slowly by mixing an ounce of resin and letting it drip in fromt he end of a toothpick, or you can do this a bit faster by using a syringe to inject it.

Keep the panel on its edge and the resin will eventually set up, strengthening the wood. Some of it may soak in, so even if you fill the void to the top there may still be a depression, and the resin will not come up to the edge, but it has done its job, and the remaining void will be much stronger and much smaller. Whatever remaisn of the void will fill in when you tape your seams.

Great syringes come with inkjet printer refill kits. Some of the kits have 4 syringes and needles (one for each color) and others just have a single syringe and long, fairly blunt needle. Apparently they expect you to wash it out thoroughly between colors. That suggests to me that if you buy the kits with the 4 syringes then 3 can go to kayak building the the last one can be kept for refilling your ink cartridge.

If you don't need the needle, don't use the needle. They are hard to clean out. However, you may be able to fill and refil the syringe with epoxy resin, applying it where needed, and then flush out the syringe with vinegar. Put an ounce of vinegar in a plastic cup, suck it into the syringe and squirt it out several times. then do another ounce. and finally a third ounce. then take the syringe apart and try to wipe off any remaining goop on the plunger. let the syringe remain apart and you may be able to reuse it several times. They are a polyethylene and any epoxy you mised washing out should flake off once it has set up. Removing that is much easier when the syringe is already open.

Of course you can also use the panels with voids as templates and trace around them onto other wood panels, making duplicates which might not have voids in them. You can make the duplicates from more cheap lauan, or you can make them from more expensive wood.

Hope this helps.

PGJ