I ran a 45 on my table saw, then sanded to get rounded. Ended up with a nice edge, but with perhaps too much radius -- around 3/8 inch. With 3/4 inch height to start with, and stickover from side panel at 7/16 inch in one place (to allow for planed angle to match deck curve), it doesn't leave much to clamp onto. But, I'm getting it. The complex curve of this shear clamp is too much for my clamping resources to get all at once, so, I'm working in several sessions. So, if someone set out to have THAT much rounding, they'd be better off using a router, after epoxying to the panel.

You've raised another point that had bothered me: attaching fittings with screws into the shear clamps -- as per instructions. I'd much rather use machine screws through the deck, with fender washers and aircraft nuts, all SS, of course. I had wondered if there was some reason this was bad with a stripper. But, from your comment, that must be a viable alternative.

: yes, roundover as much as you want. I wouldn't use the sheerclamp for any
: kind of anchor for screws through the deck or inside as the clearance to
: not go through the sheerclamp at an angle under the deck is tight. I've
: picked up a few CLC kayaks where the sheerclamp corner was not rounded
: over at all and the sheerclamp presented a sharp epoxied edge on the hand
: when finding a grip.

: You don't need a router, use a plane before putting on the sheerclamp. Not
: sure of the size of the sheerclamp but the 3/4" width is primarily to
: satisfy the installation of 1"x#10screws for deck hardware. The
: MillCreek 13 and a run WestRiver 162/4 were sold with 1/2" wide
: sheerclamps and as long as you aren't putting screws into it it's more
: than wide enough. For reference the Arctic Hawk kit only uses two piece of
: 4mm ply (3/8"wide) for a sheerclamp. I built a s&g with a sheerclamp
: that was 1/2" wide and the inside edge taken down to 1/8" under
: the deck and at the side panels leaving a triangular shape.

: Just make sure to coat the sheerclamp with adequate coats of epoxy. I've seen
: a few CLC kayaks where the sealing was inadequate at the sheerclamp and
: when the kayak was stored on it's side with standing water it found it's
: way through the seat anchor screw or gaps in the joint leaving some
: waterstaining on the outside.