: 1. The white carpenters glue I used shows through in lots of joints - looks
: bad, is their any way to correct or do I just need to build another and
: use less glue next time?
Too late now for the hull, but on the deck, wet the surface with water. This will show the areas where excess glue is on the surface. Just sand till wetting shows no defects. If the glue is a poorly fitting joint( I have had MANY )
then you should clean the glue out, fill the defect with a sliver of matching wood or thickened epoxy colored with sanding dust. I have the best luck with the epoxy route.
: 2. I have a few ugly air pockets which look really bad. Can these be cut out
: and patched with a piece of glass cloth and re-epoxied?
Yup, had lots of these too! Just cut the defect out, cut a patch of 'glass a little larger than the hole and epoxy it on. Sand the patch carefully to feather the edges, fill the weave and that's it. You shouldn't see any evidence of the patch after sanded and varnished.
: Also, where I laid a second layer of glass cloth there is a distinctive line.
: Can I now try to feather that out by sanding and will the varnish leave a
: nice finish or must I lay another coat of epoxy after I sand? I am afraid
: of getting the boat too heavy by using too much epoxy.
Sand to feather the edge of the 'glass, then fill the areas where you sanded to the weave with a thin fill coat of epoxy. You must cover any area where you sand the 'glass completely off with a patch as described earlier.
Weight, don't worry about it. The only time I notice how heavy the Guillemot is happens when I load the boat on the trailer! 2 minutes out of a great paddling day? So What!
Hope I helped,
Steve
www.steve-frederick.com