: (Wow! Lightning storm! I'll ask more silly questions later!)

An ice storm with lightning? Crazy... I hope it doesn't take the power out (there is a tree leaning on the house power line)...

Anyway...

: As said above...I drill through both sheets at the same time. I hold the
: sheets in position, drill, and wire. I basically stitch the boat together
: loosely at very widely spaced stitches, and come back to add the real
: tightening stitches after it is looking somewhat like a boat.

Well, for the first two panels this makes sense to me. For the next two it makes a little less sense. But, before I go -there-... how much of a boat does it look like? I could not, truly, even to save my life, cut straight lines with a jigsaw. I'm counting on there being gaps. They might even reach 1/2" to 1". Ok, no problem, I can cut down the bumps and lower the gaps somewhat, but how much? And how much is necessary? If I'm going to epoxy/fillet the two panels together, up to 1/4" gap might even work. (Maybe I'm just getting worried about possible problems that won't even exist when I get to that part...)

: I don't get a mess. I mix the epoxy and wood flour to a consistency that
: allows me to spread the goop nicely with a craft stick (tongue depressor).
: One has to mix the epoxy with a somewhat fiberous filler...such as wood
: flour...or it has a tendency to seek the lowest level...like viscous
: water. In your scenario...though it may not flow out a "hole",
: it will flow to puddle in the lowest spot.

Ok - so, in total, the inside fillet might be 3/8" wide (maybe 1/2")?

: I put on several coats after the weave has dissappeared, then scrape lightly
: and sand.

So you have 4 or 5 coats of epoxy? My quess is that your coats after the weave is gone are pretty thin... Hmm. How much epoxy does a boat take for you? (Do you glass inside and out?)

: It's nice to have ventilation where you work.

The living room is better ventilated than you might imagine (it's a 220 y/o house) and I do wear a respirator while doing most work. Hmm. And I covered the furniture and floor in plastic and have a shop-vac hooked up to my ROS. Damage to me and to the house are hopefully minimized. (And the fire extinguisher is only 8' away - I wouldn't want to have another fire either...)

Anyway, thanks bunches to you and mike...

cheers!
charles