I thought that epoxy was less toxic than the "ester" family. The material data safety sheets for the epoxies I have used (West System and System 3) show not enough VOCs (volatile organic compounds) to be worried about. I've worked with esters also, and the fumes can overcome you if you're not wearing a proper respirator. I haven't even noticed any fumes with epoxy (am I missing something)?
-Mike C.

: I am not a design engineer, and I like tinkering with alternatives, but I
: think you miss the point of using plywood, which is to make the craft
: lighter and gain the advantage of better fatigue resistance and also you
: get to enjoy the timeless beauty of the wood. I believe kayak plywood is
: lighter than an equivalent panel of fiberglas.

: To preform fiberglas panels, then stitch and tape them together might just be
: a cruder, less effective way of making a fiberglas boat than using a mold.
: With the mold you can lay the whole thing up in one shot and then let it
: cure, so it would be stronger, but heavier than a wood boat.

: Also, bending fiberglas panels somehow seems like a bad thing, after they
: cure. The advantage of fiberglas is you can mold in any shape while wet.

: Also, polyester is never as good as epoxy, except for the lower toxicity of
: hte fumes and the cost - its heavier, weaker and shrinks while curing.

: Maybe try exploring how to use wood and dispense with the weight of
: epoxy/fiberglass but somehow otherwise obtain the extra strength and
: protection of fiberglas skin, if you succeed you could revolutionize this
: niche.