:I am thinking about
: sanding the entire outside of the kayak down to the cedar stripping and
: redoing with the 207 hardner and 6 oz cloth. Wondering if anyone else has
: done this and what to expect.

Yes, just a couple months ago (wow, has it been that long?) I was disatisfied with my deck, and sanded the entire thing back down to wood and started over. The process wasn't as hard as I feared, and it was very satisfying once done. It gave me a good sense of satisfaction and control over the destiny of my boat.
Great confidance booster - I feel like no task is to daunting now.

You have to watch what you are doing carefully. As long as you are producing white dust, just grind away. Once you see the weave start to show through, slow it down a bit. Then, once the weave disappears and you are into the seal coat on the wood, go slowly and carefully. The epoxy doesn't soak in very far, so you won't be sanding long. As soon as you see light wood (ie: not epoxy coated wood) stop. You're done.

As you work it, work "backwards". That is, keep the finished portions in front of you, and progress backwards, not forward. This will keep the sanding pad on glass and not bare wood as you do your "tilting" and "edging" of the sander to get the fastest performance out of it. That way, if you make an error and the sander digs a little or sits too long, it will sand into glass and not wood. Hope that made sense.

I was using a newly purchased ROS (rather than my old recangular sander, and at the suggestion of this board) and the job went very well. I got the nack of the process with less than 1/5th to go, so I'm sure it would go faster a second time. So, with an improper sander for the first half, then learning the ROS for the second half, it still took only a week working a couple to a few hours each week night, and some on the weekend. I don't recall the exact number of hours, and my notes are at home.

So, yes, it is very doable and not that big a deal.

I'll leave the other questions to more knowledgable people than I.

Good luck, if you decide to do it.

Rick